Overlay systems and methods of installing overlay systems

ABSTRACT

A method of installing a binder-based overlay system may include contacting a layer of geotextile fabric to a surface of a substrate and applying a primer layer to a surface of the geotextile fabric. Two or more binder layers including infill particles may be applied over the primer layer. A resurfacer layer followed by one or more color layers may be applied over the two or more binder layers. The primer layer, one or more binder layers, resurfacer layer, and two or more color layers may cure upon application to form a monolithic layer upon the substrate.

CROSS-REFERENCES TO RELATED PATENT APPLICATION

This application is a continuation of U.S. patent application Ser. No.15/836,857, filed Dec. 9, 2017, which claims priority to U.S.Provisional Application No. 62/431,955, filed Dec. 9, 2016. U.S. patentapplication Ser. No. 15/836,857 and U.S. Provisional Application No.62/431,955 are hereby incorporated herein by reference in theirentirety.

BACKGROUND

Tennis courts, basketball courts, volleyball courts, running tracks, andother athletic playing surfaces deteriorate over time. To wit, thesecourts and surfaces develop cracks and other deformations (e.g., “lowspots”, “high spots”, “dead spots”, etc.). These deformations affect thequality of athletic activity or performance and pose an injury threat toparticipants. Thus, development of cracks and other deformationsrequires continuous maintenance. Despite advances in the understandingof the construction and maintenance of athletic courts and playingsurfaces, there still exists a need for customizable overlay systemsthat provide superior durability, improved planarity, and comfort forall participants.

BRIEF SUMMARY

Disclosed herein are binder-based overlay systems.

Disclosed herein is a binder-based overlay system comprising a layer ofseaming material; a layer of geotextile fabric; a primer layer adheredto the layer of geotextile fabric; one or more binder layers comprisingsand, rubber, or a rubber alternative, or a combination thereof adheredto the primer layer; a resurfacer layer; a first color layer; a secondcolor layer; and playing lines. Disclosed herein is a binder-basedoverlay system comprising a layer of seaming material; a layer ofgeotextile fabric; a primer layer adhered to the layer of geotextilefabric; one or more binder layers comprising sand, rubber, or a rubberalternative, or a combination thereof adhered to the primer layer; afirst resurfacer layer; a second resurfacer layer; a first color layer;a second color layer; and playing lines. Disclosed herein is abinder-based overlay system comprising a layer of geotextile fabric; aprimer layer adhered to the layer of geotextile fabric; one or morebinder layers comprising sand, rubber, or a rubber alternative, or acombination thereof adhered to the primer layer; a resurfacer layer; afirst color layer; a second color layer; and playing lines. Disclosedherein is a binder-based overlay system comprising a layer of seamingmaterial; a layer of geotextile fabric; a primer layer adhered to thelayer of geotextile fabric; one or more binder layers comprising sand,rubber, or a rubber alternative, or a combination thereof adhered to theprimer layer; a first resurfacer layer; a first color layer; a secondcolor layer; and playing lines. Disclosed herein is a binder-basedoverlay system comprising a layer of seaming material; a layer ofgeotextile fabric; a primer layer; one or more binder layers; a firstresurfacer layer; a second resurfacer layer; a first color layer; asecond color layer; and playing lines. Disclosed herein is abinder-based overlay system comprising a layer of geotextile fabric; aprimer layer; one or more binder layers; one or more resurfacer layers;one or more color layers; and playing lines. Disclosed herein is abinder-based overlay system comprising a layer of seaming material;layer of geotextile fabric; a primer layer; between 1-8 binder layers;two or more resurfacer layers; two or more color layers; and playinglines. Disclosed herein is a binder-based overlay system comprising alayer of geotextile fabric; a primer layer; and one or more binderlayers. Disclosed herein is a binder-based overlay system comprising alayer of geotextile fabric; a primer layer; and two or more binderlayers. Disclosed herein is a binder-based overlay system comprising: alayer of seaming material; a layer of geotextile fabric; a primer layer;and one or more binder layers. Disclosed herein is a binder-basedoverlay system comprising a layer of seaming material; a layer ofgeotextile fabric; a primer layer; and two or more binder layers.Disclosed herein is a binder-based overlay system comprising a layer ofseaming material; a layer of geotextile fabric; two or more primerlayers; and two or more binder layers. Disclosed herein is abinder-based overlay system comprising a layer of geotextile fabric; twoor more primer layers; and two or more binder layers. Disclosed hereinis a binder-based overlay system comprising a layer of geotextilefabric; a primer layer adhered to the layer of geotextile fabric; andone or more binder layers adhered to the primer layer. Disclosed hereinis a binder-based overlay system comprising a layer of seaming material;a layer of geotextile fabric; a primer layer adhered to the layer ofgeotextile fabric; and one or more binder layers adhered to the primerlayer. Disclosed herein is a binder-based overlay system comprising alayer of geotextile fabric; a primer layer adhered to the layer ofgeotextile fabric; and two or more binder layers adhered to the primerlayer. Disclosed herein is a binder-based overlay system, comprising alayer of seaming material; a layer of geotextile fabric; a primer layeradhered to the layer of geotextile fabric; and two or more binder layersadhered to the primer layer. Disclosed herein is a binder-based overlaysystem comprising a layer of seaming material; a layer of geotextilefabric; two or more primer layers adhered to the layer of geotextilefabric; and two or more binder layers adhered to the two or more primerlayers. Disclosed herein is a binder-based overlay system comprising alayer of geotextile fabric; two or more primer layers adhered to thelayer of geotextile fabric; and two or more binder layers adhered to thetwo or more primer layers.

Disclosed herein are methods of installing a binder-based overlaysystems.

Disclosed herein is a method of installing a binder-based overlay systemcomprising correcting one or more deformations in the existingsubstrate; contacting a layer of geotextile fabric to a surface of asubstrate; applying one or more primer layers to a surface of thegeotextile fabric; adding one or more binder layers; applying two ormore resurfacer layers; applying two or more color layers; and providingplaying lines on the surface of the overlay. Disclosed herein is amethod of installing a binder-based overlay system comprising contactinga layer of geotextile fabric to a surface of a substrate; applying oneor more primer layers to a surface of the geotextile fabric; adding oneor more binder layers; applying two or more resurfacer layers; applyingtwo or more color layers; and providing playing lines on the surface ofthe overlay. Disclosed herein is a method of installing a binder-basedoverlay system comprising correcting one or more deformations in theexisting substrate; contacting a layer of geotextile fabric to a surfaceof a substrate; applying one or more primer layers to a surface of thegeotextile fabric; adding one or more binder layers to the one or moreprimer layers; applying two or more resurfacer layers to the one or morebinder layers; applying two or more color layers to the two or moreresurfacer layers; and providing playing lines on the surface of theoverlay. Disclosed herein is a method of installing a binder-basedoverlay system comprising contacting a layer of geotextile fabric to asurface of a substrate; applying one or more primer layers to a surfaceof the geotextile fabric; adding one or more binder layers to the one ormore primer layers; applying two or more resurfacer layers to the one ormore binder layers; applying two or more color layers to the two or moreresurfacer layers; and providing playing lines on the surface of theoverlay.

Disclosed herein is a method of installing a binder-based overlay systemcomprising: correcting one or more deformations in the existingsubstrate; contacting a layer of geotextile fabric to a surface of asubstrate; applying one or more primer layers to a surface of thegeotextile fabric; adding one or more binder layers to the one or moreprimer layers; applying one or more resurfacer layers to the one or morebinder layers; applying one or more color layers to the one or moreresurfacer layers; and providing playing lines on the surface of theoverlay. Disclosed herein is a method of installing a binder-basedoverlay system comprising contacting a layer of geotextile fabric to asurface of a substrate; applying one or more primer layers to a surfaceof the geotextile fabric; adding one or more binder layers to the one ormore primer layers; applying one or more resurfacer layers to the one ormore binder layers; applying one or more color layers to the one or moreresurfacer layers; and providing playing lines on the surface of theoverlay. Disclosed herein is a method of installing a binder-basedoverlay system comprising correcting one or more deformations in theexisting substrate; contacting a layer of geotextile fabric to a surfaceof a substrate; applying one or more primer layers to a surface of thegeotextile fabric; adding one or more binder layers; applying one ormore resurfacer layers; applying one or more color layers; and providingplaying lines on the surface of the overlay. Disclosed herein is methodof installing a binder-based overlay system comprising contacting alayer of geotextile fabric to a surface of a substrate; applying one ormore primer layers to a surface of the geotextile fabric; adding one ormore binder layers; applying one or more resurfacer layers; applying oneor more color layers; and providing playing lines on the surface of theoverlay. Disclosed herein is a method of installing a binder-basedoverlay system comprising partially or substantially adhering a layer ofgeotextile fabric to the surface of a substrate; applying a primerlayer; and adding one or more binder layers. Disclosed herein is amethod of installing a binder-based overlay system, comprising:correcting one or more deformations in an existing substrate; partiallyor substantially adhering a layer of geotextile fabric to the surface ofa substrate; applying a primer layer; and adding one or more binderlayers. Disclosed herein is a method of installing a binder-basedoverlay system comprising correcting one or more deformations in thesubstrate; seaming two or more pieces of geotextile fabric to thesubstrate to create a layer of seamed geotextile fabric; partially orsubstantially adhering two or more pieces of geotextile fabric to thesubstrate; applying one or more primer layers; adding one or more binderlayers; applying one or more resurfacer layers; applying one or morecolor layers; and providing playing lines on the surface of the overlay.

Disclosed herein are infill-based overlay systems.

Disclosed herein is an infill-based overlay system, comprising: a layerof geotextile fabric; an adhesive layer; and an infill layer. Disclosedherein is an infill-based overlay system, comprising: a layer of seamingmaterial; a layer of geotextile fabric; an adhesive layer; and an infilllayer. Disclosed herein is an infill-based overlay system, comprising:at least one layer of geotextile fabric; at least one adhesive layer;and at least one infill layer. Disclosed herein is an infill-basedoverlay system, comprising: at least one layer of geotextile fabric; atleast one adhesive layer; and at least two infill layers. Disclosedherein is an infill-based overlay system, comprising: a layer ofgeotextile fabric; three adhesive layers; and two infill layers.Disclosed herein is an infill-based overlay system, comprising: a layerof geotextile fabric; four adhesive layers; and three infill layers.Disclosed herein is an infill-based overlay system, comprising: at leasttwo layers of geotextile fabric; at least one adhesive layer; and atleast one infill layer. Disclosed herein is an infill-based overlaysystem, comprising: a layer of geotextile fabric partially orsubstantially adhered to a substrate; an adhesive layer applied to thelayer of geotextile fabric; and an infill layer. Disclosed herein is aninfill-based overlay system, comprising: a layer of geotextile fabricpartially or substantially adhered to a substrate; an adhesive layerapplied to the layer of geotextile fabric; and an infill layercomprising sand, rubber, or a rubber alternative, or a combinationthereof adhered to the adhesive layer. Disclosed herein is aninfill-based overlay system, comprising: a layer of seaming material; alayer of geotextile fabric partially or substantially adhered to asubstrate; an adhesive layer applied to the layer of geotextile fabric;and an infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof adhered to the adhesive layer. Disclosed herein isan infill-based overlay system, comprising: a layer of geotextile fabricpartially or substantially adhered to a substrate; a first adhesivelayer applied to the layer of geotextile fabric; an infill layercomprising sand, rubber, or a rubber alternative, or a combinationthereof adhered to the adhesive layer; a second adhesive layer appliedto the infill layer; and at least one layer of a resurfacer. Disclosedherein is an infill-based overlay system, comprising: a layer ofgeotextile fabric partially or substantially adhered to a substrate; afirst adhesive layer applied to the layer of geotextile fabric; aninfill layer comprising sand, rubber, or a rubber alternative, or acombination thereof adhered to the adhesive layer; a second adhesivelayer applied to the infill layer; a first layer of a resurfacer; and asecond layer of a resurfacer. Disclosed herein is an infill-basedoverlay system, comprising: a layer of geotextile fabric partially orsubstantially adhered to a substrate; a first adhesive layer applied tothe layer of geotextile fabric; an infill layer comprising sand, rubber,or a rubber alternative, or a combination thereof adhered to theadhesive layer; a second adhesive layer applied to the infill layer; afirst layer of a resurfacer; a second layer of a resurfacer; and atleast one layer of a color. Disclosed herein is an infill-based overlaysystem, comprising: a layer of geotextile fabric partially orsubstantially adhered to a substrate; an adhesive layer applied to thelayer of geotextile fabric; an infill layer comprising sand, rubber, ora rubber alternative, or a combination thereof adhered to the adhesivelayer; a second adhesive layer applied to the infill layer; a firstlayer of a resurfacer; a second layer of a resurfacer; a first layer ofa color; and a second layer of a color. Disclosed herein is aninfill-based overlay system, comprising: a layer of geotextile fabricpartially or substantially adhered to a substrate; a first adhesivelayer applied to the layer of geotextile fabric; an infill layercomprising sand, rubber, or a rubber alternative, or a combinationthereof adhered to the adhesive layer; a second adhesive layer appliedto the infill layer; a first layer of a resurfacer; a second layer of aresurfacer; a first layer of a color; a second layer of a color; andplaying lines.

Disclosed herein is an infill-based overlay system, comprising: a layerof geotextile fabric partially or substantially adhered to a substrate;a first adhesive layer applied to the layer of geotextile fabric; aninfill layer comprising sand, rubber, or a rubber alternative, or acombination thereof adhered to the adhesive layer; a second adhesivelayer applied to the infill layer; a first layer of a resurfacer; asecond layer of a resurfacer; a first layer of a color; a second layerof a color; a third layer of color; and playing lines. Disclosed hereinis an infill-based overlay system, comprising: a layer of seamingmaterial; a layer of geotextile fabric partially or substantiallyadhered to a substrate; a first adhesive layer applied to the layer ofgeotextile fabric; an infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof adhered to the adhesive layer; asecond adhesive layer applied to the infill layer; a first layer of aresurfacer; a second layer of a resurfacer; a first layer of a color; asecond layer of a color; a third layer of color; and playing lines.Disclosed herein is an infill-based overlay system, comprising: a layerof geotextile fabric; a first adhesive layer; a first infill layer; asecond adhesive layer; and a second infill layer. Disclosed herein is aninfill-based overlay system, comprising: a layer of seaming material; alayer of geotextile fabric; a first adhesive layer; a first infilllayer; a second adhesive layer; and a second infill layer. Disclosedherein is an infill-based overlay system, comprising: a layer ofgeotextile fabric partially or substantially adhered to a substrate; afirst adhesive layer adhered to the layer of geotextile fabric; a firstinfill layer; a second adhesive layer adhered to the first infill layer;and a second infill layer.

Disclosed herein is an infill-based overlay system, comprising: a layerof geotextile fabric partially or substantially adhered to a substrate;a first adhesive layer adhered to the layer of geotextile fabric; afirst infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof adhered to the first adhesive layer; a secondadhesive layer adhered to the first infill layer; and a second infilllayer comprising sand, rubber, or a rubber alternative, or a combinationthereof adhered to the second adhesive layer. Disclosed herein is aninfill-based overlay system, comprising: a layer of geotextile fabricpartially or substantially adhered to a substrate; a first adhesivelayer adhered to the layer of geotextile fabric; a first infill layercomprising sand, rubber, or a rubber alternative, or a combinationthereof adhered to the first adhesive layer; a second adhesive layeradhered to the first infill layer; a second infill layer comprisingsand, rubber, or a rubber alternative, or a combination thereof adheredto the second adhesive layer; a third adhesive layer adhered to thesecond infill layer; and at least one layer of a resurfacer. Disclosedherein is an infill-based overlay system, comprising: a layer ofgeotextile fabric partially or substantially adhered to a substrate; afirst adhesive layer adhered to the layer of geotextile fabric; a firstinfill layer comprising sand, rubber, or a rubber alternative, or acombination thereof adhered to the first adhesive layer; a secondadhesive layer adhered to the first infill layer; a second infill layercomprising sand, rubber, or a rubber alternative, or a combinationthereof adhered to the second adhesive layer; a third adhesive layeradhered to the second infill layer; a first layer of a resurfacer; asecond layer of a resurfacer; and at least one layer of a color.Disclosed herein is an infill-based overlay system, comprising: a layerof geotextile fabric partially or substantially adhered to a substrate;a first adhesive layer adhered to the layer of geotextile fabric; afirst infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof adhered to the first adhesive layer; a secondadhesive layer adhered to the first infill layer; a second infill layercomprising sand, rubber, or a rubber alternative, or a combinationthereof adhered to the second adhesive layer; a third adhesive layeradhered to the second infill layer; a first layer of a resurfacer; asecond layer of a resurfacer; a first layer of a color; and a secondlayer of a color. Disclosed herein is an infill-based overlay system,comprising: a layer of geotextile fabric partially or substantiallyadhered to a substrate; a first adhesive layer adhered to the layer ofgeotextile fabric; a first infill layer comprising sand, rubber, or arubber alternative, or a combination thereof adhered to the firstadhesive layer; a second adhesive layer adhered to the first infilllayer; a second infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof adhered to the second adhesivelayer; a third adhesive layer adhered to the second infill layer; afirst layer of a resurfacer; a second layer of a resurfacer; a firstlayer of a color; a second layer of a color; and playing lines.Disclosed herein is an infill-based overlay system, comprising: a layerof geotextile fabric partially or substantially adhered to a substrate;a first adhesive layer adhered to the layer of geotextile fabric; afirst infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof adhered to the first adhesive layer; a secondadhesive layer adhered to the first infill layer; a second infill layercomprising sand, rubber, or a rubber alternative, or a combinationthereof adhered to the second adhesive layer; a third adhesive layeradhered to the second infill layer; a first layer of a resurfacer; asecond layer of a resurfacer; a first layer of a color; a second layerof a color; a third layer of a color; and playing lines. Disclosedherein is an infill-based overlay system, comprising: a layer of seamingmaterial; a layer of geotextile fabric partially or substantiallyadhered to a substrate; a first adhesive layer adhered to the layer ofgeotextile fabric; a first infill layer comprising sand, rubber, or arubber alternative, or a combination thereof adhered to the firstadhesive layer; a second adhesive layer adhered to the first infilllayer; a second infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof adhered to the second adhesivelayer; a third adhesive layer adhered to the second infill layer; afirst layer of a resurfacer; a second layer of a resurfacer; a firstlayer of a color; a second layer of a color; a third layer of a color;and playing lines. Disclosed herein is an infill-based overlay system,comprising: a layer of geotextile fabric partially or substantiallyadhered to a substrate; a first adhesive layer applied to the layer ofgeotextile fabric; a first infill layer comprising sand, rubber, or arubber alternative, or a combination thereof adhered to the firstadhesive layer; a second adhesive layer applied to the first infilllayer; a second infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof adhered to the second adhesivelayer; a third adhesive layer applied to the second infill layer; and athird infill layer comprising sand, rubber, or a combination of sand andrubber adhered to the third adhesive layer. Disclosed herein is aninfill-based overlay system, comprising: a layer of seaming material; alayer of geotextile fabric partially or substantially adhered to asubstrate; a first adhesive layer applied to the layer of geotextilefabric; a first infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof adhered to the first adhesivelayer; a second adhesive layer applied to the first infill layer; asecond infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof adhered to the second adhesive layer; a thirdadhesive layer applied to the second infill layer; and a third infilllayer comprising sand, rubber, or a rubber alternative, or a combinationthereof adhered to the third adhesive layer.

Disclosed herein is an infill-based overlay system, comprising: a layerof geotextile fabric partially or substantially adhered to a substrate;a first adhesive layer applied to the layer of geotextile fabric; afirst infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof adhered to the first adhesive layer; a secondadhesive layer applied to the first infill layer; a second infill layercomprising sand, rubber, or a rubber alternative, or a combinationthereof adhered to the second adhesive layer; a third adhesive layerapplied to the second infill layer; a third infill layer comprisingsand, rubber, or a rubber alternative, or a combination thereof adheredto the third adhesive layer. Disclosed herein is an infill-based overlaysystem, comprising: a layer of geotextile fabric partially orsubstantially adhered to a substrate; a first adhesive layer applied tothe layer of geotextile fabric; a first infill layer comprising sand,rubber, or a rubber alternative, or a combination thereof adhered to thefirst adhesive layer; a second adhesive layer applied to the firstinfill layer; a second infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof adhered to the second adhesivelayer; a third adhesive layer applied to the second infill layer; athird infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof adhered to the third adhesive layer; a fourthadhesive layer adhered to the third infill layer; a first layer of aresurfacer; and a second layer of a resurfacer. Disclosed herein is aninfill-based overlay system, comprising: a layer of geotextile fabricpartially or substantially adhered to a substrate; a first adhesivelayer applied to the layer of geotextile fabric; a first infill layercomprising sand, rubber, or a rubber alternative, or a combinationthereof adhered to the first adhesive layer; a second adhesive layerapplied to the first infill layer; a second infill layer comprisingsand, rubber, or a rubber alternative, or a combination thereof adheredto the second adhesive layer; a third adhesive layer adhered to thesecond infill layer; a third infill layer sand, rubber, or a rubberalternative, or a combination thereof adhered to the third adhesivelayer; a fourth adhesive layer adhered to the third infill layer; afirst layer of a resurfacer; a second layer of a resurfacer; and atleast one layer of color. Disclosed herein is an infill-based overlaysystem, comprising: a layer of geotextile fabric partially orsubstantially adhered to a substrate; a first adhesive layer applied tothe layer of geotextile fabric; a first infill layer sand, rubber, or arubber alternative, or a combination thereof adhered to the firstadhesive layer; a second adhesive layer applied to the first infilllayer; a second infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof adhered to the second adhesivelayer; a third adhesive layer adhered to the second infill layer; athird infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof adhered to the third adhesive layer; a fourthadhesive layer adhered to the third infill layer; a first layer of aresurfacer; a second layer of a resurfacer; a first layer of color; anda second layer of color. Disclosed herein is an infill-based overlaysystem, comprising: a layer of geotextile fabric partially orsubstantially adhered to a substrate; a first adhesive layer applied tothe layer of geotextile fabric; a first infill layer comprising sand,rubber, or a rubber alternative, or a combination thereof adhered to thefirst adhesive layer; a second adhesive layer applied to the firstinfill layer; a second infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof adhered to the second adhesivelayer; a third adhesive layer adhered to the second infill layer; athird infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof; a fourth adhesive layer adhered to the thirdinfill layer; a first layer of a resurfacer; a second layer of aresurfacer; a first layer of color; a second layer of color; and playinglines.

Disclosed herein is an infill-based overlay system, comprising: a layerof geotextile fabric partially or substantially adhered to a substrate;a first adhesive layer applied to the layer of geotextile fabric; afirst infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof adhered to the first adhesive layer; a secondadhesive layer applied to the first infill layer; a second infill layercomprising sand, rubber, or a rubber alternative, or a combinationthereof adhered to the second adhesive layer; a third adhesive layeradhered to the second infill layer; a third infill layer comprisingsand, rubber, or a rubber alternative, or a combination thereof adheredto the third adhesive layer; a fourth adhesive layer adhered to thethird infill layer; a first layer of a resurfacer; a second layer of aresurfacer; a first layer of color; a second layer of color; a thirdlayer of color; and playing lines. Disclosed herein is an infill-basedoverlay system, comprising: a layer of seaming material; a layer ofgeotextile fabric partially or substantially adhered to a substrate; afirst adhesive layer applied to the layer of geotextile fabric; a firstinfill layer comprising sand, rubber, or a rubber alternative, or acombination thereof adhered to the first adhesive layer; a secondadhesive layer applied to the first infill layer; a second infill layercomprising sand, rubber, or a rubber alternative, or a combinationthereof adhered to the second adhesive layer; a third adhesive layeradhered to the second infill layer; a third infill layer comprisingsand, rubber, or a rubber alternative, or a combination thereof adheredto the third adhesive layer; a fourth adhesive layer adhered to thethird infill layer; a first layer of a resurfacer; a second layer of aresurfacer; a first layer of color; a second layer of color; a thirdlayer of color; and playing lines. Disclosed herein is an infill-basedoverlay system, comprising: a layer of seaming material; a layer ofgeotextile fabric partially or substantially adhered to a substrate; afirst adhesive layer applied to the layer of geotextile fabric; a firstinfill layer comprising rubber or a rubber alternative, or a combinationof sand and rubber or a rubber alternative adhered to the first adhesivelayer; a second adhesive layer applied to the first infill layer; asecond infill layer comprising sand adhered to the second adhesivelayer; a third adhesive layer adhered to the second infill layer; afirst layer of a resurfacer; a second layer of a resurfacer; a firstlayer of a color; a second layer of color; and playing lines. Disclosedherein is an infill-based overlay system, comprising: a layer of seamingmaterial; a layer of geotextile fabric partially or substantiallyadhered to a substrate; a first adhesive layer applied to the layer ofgeotextile fabric; a first infill layer comprising rubber or a rubberalternative or a combination of sand and rubber or a rubber alternative,or a combination thereof adhered to the first adhesive layer; a secondadhesive layer applied to the first infill layer; a second infill layercomprising sand adhered to the second adhesive layer; a third adhesivelayer adhered to the second infill layer; a third infill layercomprising sand adhered to the third adhesive layer; a fourth adhesivelayer adhered to the third infill layer; a first layer of a resurfacer;a second layer of a resurfacer; a first layer of a color; a second layerof color; and playing lines.

Disclosed herein a method of installing an infill-based overlay system,comprising: contacting a layer of geotextile fabric to the surface of asubstrate; applying an adhesive to a surface of the geotextile fabric;and adding an infill layer to the adhesive layer. Disclosed herein amethod of installing an infill-based overlay system, comprising:contacting a layer of geotextile fabric to the surface of a substrate;applying one or more layers of adhesives; and adding one or more infilllayers. Disclosed herein a method of installing an infill-based overlaysystem, comprising: contacting a layer of geotextile fabric to thesurface of a substrate; applying an adhesive to a surface of thegeotextile fabric; and adding an infill layer comprising sand, rubber,or a rubber alternative, or a combination thereof to the adhesive layer.Disclosed herein a method of installing an infill-based overlay system,comprising: contacting a layer of geotextile fabric to the surface of asubstrate; applying one or more layers of adhesives; and adding one ormore infill layers comprising sand, rubber, or a rubber alternative, ora combination thereof. Disclosed herein a method of installing aninfill-based overlay system, comprising: correcting one or moredeformations in the existing substrate; contacting a layer of geotextilefabric to the surface of a substrate; applying an adhesive to a surfaceof the geotextile fabric; adding an infill layer to the adhesive layer.Disclosed herein a method of installing an infill-based overlay system,comprising: correcting one or more deformations in the existingsubstrate; contacting a layer of geotextile fabric to the surface of asubstrate; applying an adhesive to a surface of the geotextile fabric;adding an infill layer comprising sand, rubber, or a rubber alternative,or a combination thereof to the adhesive layer. Disclosed herein amethod of installing an infill-based overlay system, comprising:correcting one or more deformations in the existing substrate;contacting a layer of geotextile fabric to the surface of a substrate;applying one or more layers of adhesives; and adding one or more infilllayers comprising sand, rubber, or a rubber alternative, or acombination thereof. Disclosed herein a method of installing aninfill-based overlay system, comprising: correcting one or moredeformations in the existing substrate; contacting a layer of geotextilefabric to the surface of a substrate; applying one or more layers ofadhesives; and adding one or more infill layers comprising sand, rubber,or a rubber alternative, or a combination thereof. Disclosed herein amethod of installing an infill-based overlay system, comprising:contacting a layer of geotextile fabric to the surface of a substrate;applying a first adhesive layer to the surface of the geotextile fabric;adding an infill layer comprising sand, rubber, or a rubber alternative,or a combination thereof adhered to the first adhesive layer; applying asecond adhesive to the infill layer; applying at least one layer of aresurfacer; and providing playing lines on the surface of the overlay.Disclosed herein a method of installing an infill-based overlay system,comprising: contacting a layer of geotextile fabric to the surface of asubstrate; applying a first adhesive layer to the surface of thegeotextile fabric; adding an infill layer comprising sand, rubber, or arubber alternative, or a combination thereof, to the first adhesivelayer; applying a second adhesive to the infill layer; applying a firstlayer of a resurfacer; applying a second layer of a resurfacer; andproviding playing lines on the surface of the overlay. Disclosed hereina method of installing an infill-based overlay system, comprising:contacting a layer of geotextile fabric to the surface of a substrate;applying a first adhesive layer to the surface of the geotextile fabric;adding an infill layer comprising sand, rubber, or a rubber alternative,or a combination thereof to the first adhesive layer; applying a secondadhesive to the infill layer; applying a first layer of a resurfacer;applying a second layer of a resurfacer; applying at least one layer ofcolor; and providing playing lines on the surface of the overlay.Disclosed herein a method of installing an infill-based overlay system,comprising: contacting a layer of geotextile fabric to the surface of asubstrate; applying a first adhesive layer to the surface of thegeotextile fabric; adding an infill layer comprising sand, rubber, or arubber alternative, or a combination thereof to the first adhesivelayer; applying a second adhesive to the infill layer; applying a firstlayer of a resurfacer; applying a second layer of resurfacer; applying afirst layer of color; applying a second layer of color; and providingplaying lines on the surface of the overlay. Disclosed herein a methodof installing an infill-based overlay system, comprising: contacting alayer of geotextile fabric to the surface of a substrate; applying afirst adhesive layer to the surface of the geotextile fabric; adding aninfill layer comprising sand, rubber, or a rubber alternative, or acombination thereof to the first adhesive layer; applying a secondadhesive to the infill layer; applying a first layer of a resurfacer;applying a second layer of resurfacer; applying a first layer of color;applying a second layer of color; applying a third layer of color; andproviding playing lines on the surface of the overlay. Disclosed hereina method of installing an infill-based overlay system, comprising:contacting a layer of geotextile fabric to the surface of a substrate;applying a first adhesive layer to the surface of the geotextile fabric;adding a first infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof to the first adhesive layer;applying a second adhesive layer to the first infill layer; adding asecond infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof to the second adhesive layer; applying a thirdadhesive layer to the second infill layer; applying at least one layerof a resurfacer; and providing playing lines on the surface of theoverlay. Disclosed herein a method of installing an infill-based overlaysystem, comprising: contacting a layer of geotextile fabric to thesurface of a substrate; applying a first adhesive layer to the surfaceof the geotextile fabric; adding a first infill layer comprising sand,rubber, or a rubber alternative, or a combination thereof to the firstadhesive layer; applying a second adhesive layer to the first infilllayer; adding a second infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof to the second adhesive layer;applying a third adhesive layer to the second infill layer; applying afirst layer of a resurfacer; applying a second layer of a resurfacer;and providing playing lines on the surface of the overlay.

Disclosed herein a method of installing an infill-based overlay system,comprising: contacting a layer of geotextile fabric to the surface of asubstrate; applying a first adhesive layer to the surface of thegeotextile fabric; adding a first infill layer comprising sand, rubber,or a rubber alternative, or a combination thereof to the first adhesivelayer; applying a second adhesive layer to the first infill layer;adding a second infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof to the second adhesive layer;applying a third adhesive layer to the second infill layer; applying afirst layer of a resurfacer; applying a second layer of a resurfacer;applying at least one layer of color; and providing playing lines on thesurface of the overlay. Disclosed herein a method of installing aninfill-based overlay system, comprising: contacting a layer ofgeotextile fabric to the surface of a substrate; applying a firstadhesive layer to the surface of the geotextile fabric; adding a firstinfill layer comprising sand, rubber, or a rubber alternative, or acombination thereof to the first adhesive layer; applying a secondadhesive layer to the first infill layer; adding a second infill layercomprising sand, rubber, or a rubber alternative, or a combinationthereof to the second adhesive layer; applying a third adhesive layer tothe second infill layer; applying a first layer of a resurfacer;applying a second layer of a resurfacer; applying a first layer ofcolor; applying a second layer of color; and providing playing lines onthe surface of the overlay. Disclosed herein a method of installing aninfill-based overlay system, comprising: contacting a layer ofgeotextile fabric to the surface of a substrate; applying a firstadhesive layer to the surface of the geotextile fabric; adding a firstinfill layer comprising sand, rubber, or a rubber alternative, or acombination thereof to the first adhesive layer; applying a secondadhesive layer to the first infill layer; adding a second infill layercomprising sand, rubber, or a rubber alternative, or a combinationthereof to the second adhesive layer; applying a third adhesive layer tothe second infill layer; applying a first layer of a resurfacer;applying a second layer of a resurfacer; applying a first layer ofcolor; applying a second layer of color; applying a third layer ofcolor; and providing playing lines on the surface of the overlay.Disclosed herein a method of installing an infill-based overlay system,comprising: contacting a layer of geotextile fabric to the surface of asubstrate; applying a first adhesive layer to the surface of thegeotextile fabric; adding a first infill layer comprising sand, rubber,or a rubber alternative, or a combination thereof to the first adhesivelayer; applying a second adhesive layer to the first infill layer;adding a second infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof to the second adhesive layer;applying a third adhesive layer to the second infill layer; adding athird infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof to the third adhesive layer; applying a fourthadhesive layer to the third infill layer; applying at least one layer ofa resurfacer; and providing playing lines on the surface of the overlay.Disclosed herein a method of installing an infill-based overlay system,comprising: contacting a layer of geotextile fabric to the surface of asubstrate; applying a first adhesive layer to the surface of thegeotextile fabric; adding a first infill layer comprising sand, rubber,or a or a rubber alternative, or a combination thereof to the firstadhesive layer; applying a second adhesive layer to the first infilllayer; adding a second infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof to the second adhesive layer;applying a third adhesive layer to the second infill layer; adding athird infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof to the third adhesive layer; applying a fourthadhesive layer to the third infill layer; applying a first layer of aresurfacer; applying a second layer of a resurfacer; and providingplaying lines on the surface of the overlay. Disclosed herein a methodof installing an infill-based overlay system, comprising: contacting alayer of geotextile fabric to the surface of a substrate; applying afirst adhesive layer to the surface of the geotextile fabric; adding afirst infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof to the first adhesive layer; applying a secondadhesive layer to the first infill layer; adding a second infill layercomprising sand, rubber, or a rubber alternative, or a combinationthereof to the second adhesive layer; applying a third adhesive layer tothe second infill layer; adding a third infill layer comprising sand,rubber, or a rubber alternative, or a combination thereof to the thirdadhesive layer; applying a fourth adhesive layer to the third infilllayer; applying a first layer of a resurfacer; applying a second layerof a resurfacer; applying at least one layer of color; and providingplaying lines on the surface of the overlay.

Disclosed herein a method of installing an infill-based overlay system,comprising: contacting a layer of geotextile fabric to the surface of asubstrate; applying a first adhesive layer to the surface of thegeotextile fabric; adding a first infill layer comprising sand, rubber,or a rubber alternative, or a combination thereof to the first adhesivelayer; applying a second adhesive layer to the first infill layer;adding a second infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof to the second adhesive layer;applying a third adhesive layer to the second infill layer; adding athird infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof to the third adhesive layer; applying a fourthadhesive layer to the third infill layer; applying a first layer of aresurfacer; applying a second layer of a resurfacer; applying a firstlayer of color; applying a second layer of color; and providing playinglines on the surface of the overlay. Disclosed herein a method ofinstalling an infill-based overlay system, comprising: contacting alayer of geotextile fabric to the surface of a substrate; applying afirst adhesive layer to the surface of the geotextile fabric; adding afirst infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof to the first adhesive layer; applying a secondadhesive layer to the first infill layer; adding a second infill layercomprising sand, rubber, or a rubber alternative, or a combinationthereof to the second adhesive layer; applying a third adhesive layer tothe second infill layer; adding a third infill layer comprising sand,rubber, or a rubber alternative, or a combination thereof to the thirdadhesive layer; applying a fourth adhesive layer to the third infilllayer; applying a first layer of a resurfacer; applying a second layerof a resurfacer; applying a first layer of color; applying a secondlayer of color; applying a third layer of color; and providing playinglines on the surface of the overlay. Disclosed herein a method ofinstalling an infill-based overlay system, comprising: correcting one ormore deformations in the substrate; contacting the substrate with two ormore pieces of geotextile fabric; inserting a seaming material under theedges of two adjacent pieces of geotextile fabric; applying a firstadhesive layer to the top surface of the seaming material; contactingthe two adjacent pieces of geotextile fabric with the adhesive on thetop surface of the seaming material; applying pressure to the seam ofthe two adjacent pieces of geotextile fabric to create a layer of seamedgeotextile fabric; applying a second adhesive layer to the surface ofthe layer of seamed geotextile fabric; adding an infill layer comprisingsand, rubber, or a rubber alternative, or a combination thereof to thesecond adhesive layer; applying a third adhesive layer to the surface ofthe infill layer; applying at least one layer of a resurfacer; applyingat least one layer of color; and providing playing lines on the surfaceof the overlay. Disclosed herein a method of installing an infill-basedoverlay system, comprising: correcting one or more deformations in thesubstrate; contacting the substrate with two or more pieces ofgeotextile fabric; inserting a seaming material under the edges of twoadjacent pieces of geotextile fabric; applying a first adhesive layer tothe top surface of the seaming material; contacting the two adjacentpieces of geotextile fabric with the adhesive on the top surface of theseaming material; applying pressure to the seam of the two adjacentpieces of geotextile fabric to create a layer of seamed geotextilefabric; applying a second adhesive layer to the surface of the layer ofseamed geotextile fabric; adding a first infill layer comprising sand,rubber, or a rubber alternative, or a combination thereof to the secondadhesive layer; applying a third adhesive layer to the surface of thefirst infill layer; adding a second infill layer comprising sand,rubber, or a rubber alternative, or a combination thereof to the secondadhesive layer; applying a fourth adhesive layer to the surface of thesecond infill layer; applying at least one layer of a resurfacer;applying at least one layer of color; and providing playing lines on thesurface of the overlay. Disclosed herein a method of installing aninfill-based overlay system, comprising: correcting one or moredeformations in the substrate; contacting the substrate with two or morepieces of geotextile fabric; inserting a seaming material under theedges of two adjacent pieces of geotextile fabric; applying a firstadhesive layer to the top surface of the seaming material; contactingthe two adjacent pieces of geotextile fabric with the adhesive on thetop surface of the seaming material; applying pressure to the seam ofthe two adjacent pieces of geotextile fabric to create a layer of seamedgeotextile fabric; applying a second adhesive layer to the surface ofthe layer of seamed geotextile fabric; adding a first infill layercomprising sand, rubber, or a rubber alternative, or a combinationthereof to the second adhesive layer; applying a third adhesive layer tothe surface of the first infill layer; adding a second infill layercomprising sand, rubber, or a rubber alternative, or a combinationthereof to the second adhesive layer; applying a fourth adhesive layerto the surface of the second infill layer; adding a third infill layercomprising sand, rubber, or a rubber alternative, or a combinationthereof to the second adhesive layer; applying a fifth adhesive layer tothe surface of the third infill layer; applying at least one layer of aresurfacer; applying at least one layer of color; and providing playinglines on the surface of the overlay.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a cross-sectional schematic of a disclosed installedbinder-based overlay system (100), comprising (101) a substrate, (102) aseaming material adhered to the underside of (103) the layer ofgeotextile fabric, (104) a fiberglass mesh over the seam, (105) a primerlayer adhered to the top layer of geotextile fabric, (106) one or morebinder layers (e.g., (106)(a)-106(h)), (107) a resurfacer layer, (108)two color layers (e.g., (108)(a)-108(b)), and (109) playing lines.

FIG. 2 shows a cross-sectional schematic of a disclosed installedinfill-based overlay system (200), comprising (201) a substrate, (202) aseaming material adhered to (203) the layer of geotextile fabric, (204)a fiberglass mesh over the seam, (205) a primer layer, (206) one or morebinder layers, (207) one or more resurfacer layers, (208) one or morecolor layers, and (209) playing lines.

FIG. 3 shows (A) an exemplary rollout pattern of pieces of geotextilefabric, (B) the overlap of two pieces of geotextile fabric, and (C) theseam that will be created following the cut in the overlap shown in (B).

FIG. 4 shows (A) the “on”/“off” pattern of an adhesive (e.g.,non-continuous application) around the perimeter of a rectangular shapedoverlay, and (B) the continuous application of an adhesive around theperimeter of a rectangular shaped overlay.

FIG. 5 shows an example of a prior art notched squeegee.

FIG. 6 shows an example of a prior art squeegee.

FIG. 7 shows an example of a prior art straight edge or screed.

DETAILED DESCRIPTION

The present invention can be understood more readily by reference to thefollowing detailed description of the invention.

Before the present systems and/or methods are disclosed and described,it is to be understood that they are not limited to specific syntheticmethods unless otherwise specified, or to particular reagents unlessotherwise specified, as such may, of course, vary. It is also to beunderstood that the terminology used herein is for the purpose ofdescribing particular aspects only and is not intended to be limiting.Although any methods and materials similar or equivalent to thosedescribed herein can be used in the practice or testing of the presentinvention, example methods and materials are now described.

All publications mentioned herein are incorporated herein by referenceto disclose and describe the methods and/or materials in connection withwhich the publications are cited. The publications discussed herein areprovided solely for their disclosure prior to the filing date of thepresent application. Nothing herein is to be construed as an admissionthat the present invention is not entitled to antedate such publicationby virtue of prior invention.

Definitions

As used in the specification and the appended claims, the singular forms“a”, “an”, and “the” include plural referents unless the context clearlydictates otherwise.

The phrase “consisting essentially of” limits the scope of a claim tothe recited components in a composition or the recited steps in a methodas well as those that do not materially affect the basic and novelcharacteristic or characteristics of the claimed composition or claimedmethod. The phrase “consisting of” excludes any component, step, orelement that is not recited in the claim. The phrase “comprising” issynonymous with “including”, “containing”, or “characterized by”, and isinclusive or open-ended. “Comprising” does not exclude additional,unrecited components or steps.

As used herein, when referring to any numerical value, the term “about”means a value falling within a range that is ±10% of the stated value.

Ranges can be expressed herein as from “about” one particular value,and/or to “about” another particular value. When such a range isexpressed, a further aspect includes from the one particular valueand/or to the other particular value. Similarly, when values areexpressed as approximations, by use of the antecedent “about,” it willbe understood that the particular value forms a further aspect. It willbe further understood that the endpoints of each of the ranges aresignificant both in relation to the other endpoint and independently ofthe other endpoint. It is also understood that there are a number ofvalues disclosed herein, and that each value is also herein disclosed as“about” that particular value in addition to the value itself. Forexample, if the value “10” is disclosed, then “about 10” is alsodisclosed. It is also understood that each unit between two particularunits are also disclosed. For example, if 10 and 15 are disclosed, then11, 12, 13, and 14 are also disclosed.

References in the specification and concluding claims to parts by weightof a particular element or component in a composition denotes the weightrelationship between the element or component and any other elements orcomponents in the composition or article for which a part by weight isexpressed. Thus, in a compound containing 2 parts by weight component Xand 5 parts by weight component Y, X and Y are present at a weight ratioof 2:5, and are present in such ratio regardless of whether additionalcomponents are contained in the compound.

As used herein, the terms “optional” or “optionally” means that thesubsequently described event or circumstance can or cannot occur, andthat the description includes instances where said event or circumstanceoccurs and instances where it does not. In an aspect, a disclosed methodcan optionally comprise one or more additional steps, such as, forexample, repeating an administering step or altering an administeringstep.

As used herein, the term “prevent” or “preventing” refers to precluding,averting, obviating, forestalling, stopping, or hindering something fromhappening, especially by advance action. It is understood that wherereduce, inhibit, or prevent are used herein, unless specificallyindicated otherwise, the use of the other two words is also expresslydisclosed. In an aspect, the disclosed overlay systems prevent theformation of cracks and other deformations in an athletic court (e.g., abasketball court, a volleyball court, a racquet ball court, a tenniscourt, a track, etc.) or some other playing surface.

As used herein, “modifying the method” can comprise modifying orchanging one or more features or aspects of one or more steps of adisclosed method. For example, in an aspect, a disclosed method can bealtered by changing the number of infill layers or the type of infilllayers installed in a disclosed overlay system. For example, in anaspect, a disclosed method can be altered by changing the number ofbinder layers or the type off binder layers installed in a disclosedoverlay system. In an aspect, modifying a method can be used tocustomize the overlay to an existing substrate or climate, especiallymodifying the content or number of binder layers or infill layers.

The term “contacting” or “applying” as used herein refers to bringing acomponent together with a target area or intended target area in such amanner that the component can exert an effect on the intended target ortargeted area either directly or indirectly. A target or intended targetarea can be a substrate, a layer or geotextile fabric, a binder layer,an infill layer, a seaming material, an adhesive layer, a resurfacerlayer, a color layer, or a combination thereof.

The term “mixing” as used in a disclosed method means to physicallycombine the recited components so as to achieve a homogenous formulationor solution. In an aspect, the recited components can be shaken, orstirred, or agitated so as to achieve a homogenous formulation orsolution. In an aspect, “mixing” can also include sifting the homogenousformulation or solution though a fine mesh strainer. The mixing can begenerally performed for a pre-determined amount of time, i.e., for 10seconds, 20 seconds, 30 seconds, 45 seconds, 1 minute, 5 minute, 10minutes, 20 minutes, 30 minutes, 40 minutes, 50 minutes, 1 hour, 2hours, 3 hours, or more. A person skilled in the art could ascertainwithout undue experimentation, the amount of time required to mix therecited components so as to achieve a homogenous formulation orsolution. In an aspect, “mixing” can be occur prior to or at the time ofinstallation. For example, a binder can be mixed with sand, rubber, or arubber alternative, or a combination thereof at the time of adding thebinder layer to the primer

The term “drying” means the process of allowing the applied or addedlayer to remain undisturbed for a period of time so as to no longer bewet or moist.

As used herein, “effective amount” and “amount effective” can refer toan amount that is sufficient to achieve the desired result such as, forexample, adhering a layer of the overlay to another layer or adhering alayer of the overlay to the substrate.

Disclosed are the components to be used to prepare a disclosed overlaysystem as well as the components used within the methods disclosedherein. These and other materials are disclosed herein, and it isunderstood that when combinations, subsets, interactions, groups, etc.of these materials are disclosed that while specific reference of eachvarious individual and collective combinations and permutation of thesesystems cannot be explicitly disclosed, each is specificallycontemplated and described herein. For example, if a particular systemis disclosed and discussed and a number of modifications that can bemade to that system are discussed, specifically contemplated is each andevery combination and permutation of the compound and the modificationsthat are possible unless specifically indicated to the contrary. Thisconcept applies to all aspects of this application including, but notlimited to, steps in methods of making and installing the disclosedoverlay systems. Thus, if there are a variety of additional steps thatcan be performed it is understood that each of these additional stepscan be performed with any specific embodiment or combination ofembodiments of the methods of the invention.

Compositions

Disclosed herein are binder-based and infill-based overlay systems.

Overlay Systems (Binder-Based)

Disclosed herein are binder-based overlay systems. Disclosed herein arebinder-based overlay systems that can be used indoors or outdoors. In anaspect, a disclosed binder-based overlay system can be used to provide avariety of athletic playing surfaces. For example, in an aspect, anbinder-based overlay system can be used to provide an indoor or anoutdoor tennis court, a pickle ball court, a basketball court, a track(e.g., an oblong running track), a racquet ball court, a volleyballcourt, or a badminton court.

Disclosed herein is an overlay system comprising a layer of seamingmaterial; a layer of geotextile fabric; a primer layer adhered to thelayer of geotextile fabric; one or more binder layers comprising sand,rubber, or a rubber alternative, or a combination thereof adhered to theprimer layer; a resurfacer layer; a first color layer; a second colorlayer; and playing lines.

Disclosed herein is an overlay system comprising a layer of seamingmaterial; a layer of geotextile fabric; a primer layer adhered to thelayer of geotextile fabric; one or more binder layers comprising sand,rubber, or a rubber alternative, or a combination thereof adhered to theprimer layer; a first resurfacer layer; a second resurfacer layer; afirst color layer; a second color layer; and playing lines.

Disclosed herein is an overlay system comprising a layer of geotextilefabric; a primer layer adhered to the layer of geotextile fabric; one ormore binder layers comprising sand, rubber, or a rubber alternative, ora combination thereof adhered to the primer layer; a resurfacer layer; afirst color layer; a second color layer; and playing lines.

Disclosed herein is an overlay system comprising a layer of seamingmaterial; a layer of geotextile fabric; a primer layer adhered to thelayer of geotextile fabric; one or more binder layers comprising sand,rubber, or a rubber alternative, or a combination thereof adhered to theprimer layer; a resurfacer layer; a first color layer; a second colorlayer; and playing lines. For example, FIG. 1 shows a cross-sectionalschematic of a disclosed installed primer-based overlay system. In FIG.1, the overlay system (100) comprises (101) a substrate, (102) a seamingmaterial adhered to the underside of (103) the layer of geotextilefabric, (104) a fiberglass mesh over the seam, (105) a primer layeradhered to the top layer of geotextile fabric, (106) one or more binderlayers (e.g., 106(a)-106(h)), (107) a resurfacer layer, (108) two colorlayers (e.g., 108(a)-108(b)), and (109) playing lines.

Disclosed herein is an overlay system comprising a layer of seamingmaterial; a layer of geotextile fabric; a primer layer; one or morebinder layers; a first resurfacer layer; a second resurfacer layer; afirst color layer; a second color layer; and playing lines.

Disclosed herein is an overlay system comprising a layer of geotextilefabric; a primer layer; one or more binder layers; one or moreresurfacer layers; one or more color layers; and playing lines. Forexample, FIG. 2 shows a cross-sectional schematic of an installeddisclosed infill-based overlay system (200). In FIG. 2, the overlaysystem (200) comprises (201) a substrate, (202) a seaming materialadhered to (203) the layer of geotextile fabric, (204) a fiberglass meshover the seam, (205) a primer layer, (206) one or more binder layers,(207) one or more resurfacer layers, (208) one or more color layers, and(209) playing lines. FIG. 2 shows fiberglass mesh over the seam in(204), which can be optionally added.

Disclosed herein is an overlay system comprising a layer of seamingmaterial; layer of geotextile fabric; a primer layer; between 1-8 binderlayers; two or more resurfacer layers; two or more color layers; andplaying lines.

Disclosed herein is an overlay system comprising a layer of geotextilefabric; a primer layer; and one or more binder layers. Disclosed hereinan overlay system comprising: a layer of seaming material; a layer ofgeotextile fabric; a primer layer; and one or more binder layers.

Disclosed herein an overlay system comprising a layer of geotextilefabric; a primer layer; and two or more binder layers. Disclosed hereinis an overlay system comprising a layer of seaming material; a layer ofgeotextile fabric; a primer layer; and two or more binder layers.

Disclosed herein is an overlay system comprising a layer of seamingmaterial; a layer of geotextile fabric; two or more primer layers; andtwo or more binder layers. Disclosed herein is an overlay systemcomprising a layer of geotextile fabric; two or more primer layers; andtwo or more binder layers.

Disclosed herein is an overlay system comprising a layer of geotextilefabric; a primer layer adhered to the layer of geotextile fabric; andone or more binder layers adhered to the primer layer. Disclosed hereinis an overlay system comprising a layer of seaming material; a layer ofgeotextile fabric; a primer layer adhered to the layer of geotextilefabric; and one or more binder layers adhered to the primer layer.

Disclosed herein is an overlay system comprising a layer of geotextilefabric; a primer layer adhered to the layer of geotextile fabric; andtwo or more binder layers adhered to the primer layer. Disclosed hereinis an overlay system, comprising a layer of seaming material; a layer ofgeotextile; a primer layer adhered to the layer of geotextile fabric;and two or more binder layers adhered to the primer layer.

Disclosed herein is an overlay system comprising a layer of seamingmaterial; a layer of geotextile fabric; two or more primer layersadhered to the layer of geotextile fabric; and two or more binder layersadhered to the two or more primer layers.

Disclosed herein is an overlay system comprising a layer of geotextilefabric; two or more primer layers adhered to the layer of geotextilefabric; and two or more binder layers adhered to the two or more primerlayers.

Overlay Systems (Infill-Based)

Disclosed herein are infill-based overlay systems. Disclosed herein areinfill-based overlay systems that can be used indoors or outdoors. In anaspect, a disclosed infill-based overlay system can be used to provide avariety of athletic playing surfaces. For example, in an aspect, aninfill-based overlay system can be used to provide an indoor or anoutdoor tennis court, a pickle ball court, a basketball court, a track(e.g., an oblong running track), a racquet ball court, a volleyballcourt, or a badminton court.

1. Infill Layer

Disclosed herein is an overlay system, comprising: a layer of geotextilefabric; an adhesive layer; and an infill layer. Disclosed herein is anoverlay system, comprising: a layer of seaming material; a layer ofgeotextile fabric; an adhesive layer; and an infill layer. Disclosedherein is an overlay system, comprising: at least one layer ofgeotextile fabric; at least one adhesive layer; and at least one infilllayer.

Disclosed herein is an overlay system, comprising: a layer of geotextilefabric; an adhesive layer applied to the layer of geotextile fabric; andan infill layer. Disclosed herein is an overlay system, comprising: alayer of geotextile fabric; an adhesive layer applied to the layer ofgeotextile fabric; and an infill layer comprising sand, rubber, or arubber alternative, or a combination thereof adhered to the adhesivelayer. Disclosed herein is an overlay system, comprising: a layer ofseaming material; a layer of geotextile fabric; an adhesive layerapplied to the layer of geotextile fabric; and an infill layercomprising sand, rubber, or a rubber alternative, or a combinationthereof adhered to the adhesive layer. Disclosed herein is an overlaysystem, comprising: a layer of geotextile fabric; a first adhesive layerapplied to the layer of geotextile fabric; an infill layer comprisingsand, rubber, or a rubber alternative, or a combination thereof adheredto the adhesive layer; a second adhesive layer applied to the infilllayer; and at least one layer of a resurfacer.

Disclosed herein is an overlay system, comprising: a layer of geotextilefabric; a first adhesive layer applied to the layer of geotextilefabric; an infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof adhered to the adhesive layer; asecond adhesive layer applied to the infill layer; a first layer of aresurfacer; and a second layer of a resurfacer.

Disclosed herein is an overlay system, comprising: a layer of geotextilefabric; a first adhesive layer applied to the layer of geotextilefabric; an infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof adhered to the adhesive layer; asecond adhesive layer applied to the infill layer; a first layer of aresurfacer; a second layer of a resurfacer; and at least one layer of acolor.

Disclosed herein is an overlay system, comprising: a layer of geotextilefabric; an adhesive layer applied to the layer of geotextile fabric; aninfill layer comprising sand, rubber, or a rubber alternative, or acombination thereof adhered to the adhesive layer; a second adhesivelayer applied to the infill layer; a first layer of a resurfacer; asecond layer of a resurfacer; a first layer of a color; and a secondlayer of a color.

Disclosed herein is an overlay system, comprising: a layer of geotextilefabric partially or substantially adhered to a substrate; a firstadhesive layer applied to the layer of geotextile fabric; an infilllayer comprising sand, rubber, or a rubber alternative, or a combinationthereof adhered to the adhesive layer; a second adhesive layer appliedto the infill layer; a first layer of a resurfacer; a second layer of aresurfacer; a first layer of a color; a second layer of a color; andplaying lines. For example, FIG. 1 shows a cross-sectional schematic ofan installed disclosed overlay system.

Disclosed herein is an overlay system, comprising: a layer of geotextilefabric; a first adhesive layer applied to the layer of geotextilefabric; an infill layer comprising sand, rubber, or a combination ofsand and rubber adhered to the adhesive layer; a second adhesive layerapplied to the infill layer; a first layer of a resurfacer; a secondlayer of a resurfacer; a first layer of a color; a second layer of acolor; a third layer of color; and playing lines.

Disclosed herein is an overlay system, comprising: a layer of seamingmaterial; a layer of geotextile fabric; a first adhesive layer appliedto the layer of geotextile fabric; an infill layer comprising sand,rubber, or a combination of sand and rubber adhered to the adhesivelayer; a second adhesive layer applied to the infill layer; a firstlayer of a resurfacer; a second layer of a resurfacer; a first layer ofa color; a second layer of a color; a third layer of color; and playinglines.

In an aspect of a disclosed overlay having at least 1 infill layer orone or more infill layers, the layer of geotextile fabric can bepartially adhered or substantially adhered to a substrate, or in anaspect, the layer of geotextile fabric can be positioned but not adheredover a substrate.

2. Infill Layers

Disclosed herein is an overlay system, comprising: at least one layer ofgeotextile fabric; at least one adhesive layer; and at least two infilllayers. Disclosed herein is an overlay system, comprising: a layer ofgeotextile fabric; three adhesive layers; and two infill layers.Disclosed herein is an overlay system, comprising: a layer of geotextilefabric; a first adhesive layer; a first infill layer; a second adhesivelayer; and a second infill layer. Disclosed herein is an overlay system,comprising: a layer of seaming material; a layer of geotextile fabric; afirst adhesive layer; a first infill layer; a second adhesive layer; anda second infill layer.

Disclosed herein is an overlay system, comprising: a layer of geotextilefabric; a first adhesive layer adhered to the layer of geotextilefabric; a first infill layer; a second adhesive layer adhered to thefirst infill layer; and a second infill layer. Disclosed herein is anoverlay system, comprising: a layer of geotextile fabric; a firstadhesive layer adhered to the layer of geotextile fabric; a first infilllayer comprising sand, rubber, or a rubber alternative, or a combinationthereof adhered to the first adhesive layer; a second adhesive layeradhered to the first infill layer; and a second infill layer comprisingsand, rubber, or a rubber alternative, or a combination thereof adheredto the second adhesive layer.

Disclosed herein is an overlay system, comprising: a layer of geotextilefabric; a first adhesive layer adhered to the layer of geotextilefabric; a first infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof adhered to the first adhesivelayer; a second adhesive layer adhered to the first infill layer; asecond infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof adhered to the second adhesive layer; a thirdadhesive layer adhered to the second infill layer; and at least onelayer of a resurfacer.

Disclosed herein is an overlay system, comprising: a layer of geotextilefabric; a first adhesive layer adhered to the layer of geotextilefabric; a first infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof adhered to the first adhesivelayer; a second adhesive layer adhered to the first infill layer; asecond infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof adhered to the second adhesive layer; a thirdadhesive layer adhered to the second infill layer; a first layer of aresurfacer; a second layer of a resurfacer; and at least one layer of acolor.

Disclosed herein is an overlay system, comprising: a layer of geotextilefabric; a first adhesive layer adhered to the layer of geotextilefabric; a first infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof adhered to the first adhesivelayer; a second adhesive layer adhered to the first infill layer; asecond infill layer comprising or a rubber alternative, or a combinationthereof adhered to the second adhesive layer; a third adhesive layeradhered to the second infill layer; a first layer of a resurfacer; asecond layer of a resurfacer; a first layer of a color; and a secondlayer of a color.

Disclosed herein is an overlay system, comprising: a layer of geotextilefabric; a first adhesive layer adhered to the layer of geotextilefabric; a first infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof adhered to the first adhesivelayer; a second adhesive layer adhered to the first infill layer; asecond infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof adhered to the second adhesive layer; a thirdadhesive layer adhered to the second infill layer; a first layer of aresurfacer; a second layer of a resurfacer; a first layer of a color; asecond layer of a color; and playing lines.

Disclosed herein is an overlay system, comprising: a layer of geotextilefabric; a first adhesive layer adhered to the layer of geotextilefabric; a first infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof adhered to the first adhesivelayer; a second adhesive layer adhered to the first infill layer; asecond infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof adhered to the second adhesive layer; a thirdadhesive layer adhered to the second infill layer; a first layer of aresurfacer; a second layer of a resurfacer; a first layer of a color; asecond layer of a color; a third layer of a color; and playing lines.

Disclosed herein is an overlay system, comprising: a layer of seamingmaterial; a layer of geotextile fabric; a first adhesive layer adheredto the layer of geotextile fabric; a first infill layer comprising sand,rubber, or a rubber alternative, or a combination thereof adhered to thefirst adhesive layer; a second adhesive layer adhered to the firstinfill layer; a second infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof adhered to the second adhesivelayer; a third adhesive layer adhered to the second infill layer; afirst layer of a resurfacer; a second layer of a resurfacer; a firstlayer of a color; a second layer of a color; a third layer of a color;and playing lines.

Disclosed herein is an overlay system, comprising: a layer of seamingmaterial; a layer of geotextile; a first adhesive layer applied to thelayer of geotextile fabric; a first infill layer comprising rubber or acombination of sand and rubber adhered to the first adhesive layer; asecond adhesive layer applied to the first infill layer; a second infilllayer comprising sand adhered to the second adhesive layer; a thirdadhesive layer adhered to the second infill layer; a first layer of aresurfacer; a second layer of a resurfacer; a first layer of a color; asecond layer of color; and playing lines.

In an aspect of a disclosed overlay having at least 2 infill layers or 2or more infill layers, the layer of geotextile fabric can be partiallyadhered or substantially adhered to a substrate, or in an aspect, thelayer of geotextile fabric can be positioned but not adhered over asubstrate.

3. Infill Layers

Disclosed herein is an overlay system, comprising: a layer of geotextilefabric; four adhesive layers; and three infill layers. Disclosed hereinis an overlay system, comprising: a layer of geotextile fabric; a firstadhesive layer; a first infill layer; a second adhesive layer; a secondinfill layer, a third adhesive layer, and a third infill layer.

Disclosed herein is an overlay system, comprising: a layer of geotextilefabric; a first adhesive layer applied to the layer of geotextilefabric; a first infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof adhered to the first adhesivelayer; a second adhesive layer applied to the first infill layer; asecond infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof to the second adhesive layer; a third adhesivelayer applied to the second infill layer; and a third infill layercomprising sand, rubber, or a combination of sand and rubber adhered tothe third adhesive layer.

Disclosed herein is an overlay system, comprising: a layer of seamingmaterial; a layer of geotextile fabric; a first adhesive layer appliedto the layer of geotextile fabric; a first infill layer comprising sand,rubber, or a rubber alternative, or a combination thereof adhered to thefirst adhesive layer; a second adhesive layer applied to the firstinfill layer; a second infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof adhered to the second adhesivelayer; a third adhesive layer applied to the second infill layer; and athird infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof adhered to the third adhesive layer.

Disclosed herein is an overlay system, comprising: a layer of geotextilefabric; a first adhesive layer applied to the layer of geotextilefabric; a first infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof adhered to the first adhesivelayer; a second adhesive layer applied to the first infill layer; asecond infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof adhered to the second adhesive layer; a thirdadhesive layer applied to the second infill layer; a third infill layercomprising sand, rubber, or a rubber alternative, or a combinationthereof adhered to the third adhesive layer.

Disclosed herein is an overlay system, comprising: a layer of geotextilefabric; a first adhesive layer applied to the layer of geotextilefabric; a first infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof adhered to the first adhesivelayer; a second adhesive layer applied to the first infill layer; asecond infill layer comprising sand, rubber or a rubber alternative, ora combination thereof adhered to the second adhesive layer; a thirdadhesive layer applied to the second infill layer; a third infill layercomprising sand, rubber or a rubber alternative, or a combinationthereof adhered to the third adhesive layer; a fourth adhesive layeradhered to the third infill layer; a first layer of a resurfacer; and asecond layer of a resurfacer.

Disclosed herein is an overlay system, comprising: a layer of geotextilefabric; a first adhesive layer applied to the layer of geotextilefabric; a first infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof adhered to the first adhesivelayer; a second adhesive layer applied to the first infill layer; asecond infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof adhered to the second adhesive layer; a thirdadhesive layer adhered to the second infill layer; a third infill layersand, rubber, or a rubber alternative, or a combination thereof adheredto the third adhesive layer; a fourth adhesive layer adhered to thethird infill layer; a first layer of a resurfacer; a second layer of aresurfacer; and at least one layer of color.

Disclosed herein is an overlay system, comprising: a layer ofgeotextile; a first adhesive layer applied to the layer of geotextilefabric; a first infill layer sand, rubber, or a rubber alternative, or acombination thereof adhered to the first adhesive layer; a secondadhesive layer applied to the first infill layer; a second infill layercomprising sand, rubber, or a rubber alternative, or a combinationthereof adhered to the second adhesive layer; a third adhesive layeradhered to the second infill layer; a third infill layer comprisingsand, rubber, or a rubber alternative, or a combination thereof adheredto the third adhesive layer; a fourth adhesive layer adhered to thethird infill layer; a first layer of a resurfacer; a second layer of aresurfacer; a first layer of color; and a second layer of color.

Disclosed herein is an overlay system, comprising: a layer of geotextilefabric; a first adhesive layer applied to the layer of geotextilefabric; a first infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof adhered to the first adhesivelayer; a second adhesive layer applied to the first infill layer; asecond infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof adhered to the second adhesive layer; a thirdadhesive layer adhered to the second infill layer; a third infill layercomprising sand, rubber, or a rubber alternative, or a combinationthereof; a fourth adhesive layer adhered to the third infill layer; afirst layer of a resurfacer; a second layer of a resurfacer; a firstlayer of color; a second layer of color; and playing lines.

Disclosed herein is an overlay system, comprising: a layer of geotextilefabric; a first adhesive layer applied to the layer of geotextilefabric; a first infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof adhered to the first adhesivelayer; a second adhesive layer applied to the first infill layer; asecond infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof adhered to the second adhesive layer; a thirdadhesive layer adhered to the second infill layer; a third infill layercomprising sand, rubber, or a rubber alternative, or a combinationthereof adhered to the third adhesive layer; a fourth adhesive layeradhered to the third infill layer; a first layer of a resurfacer; asecond layer of a resurfacer; a first layer of color; a second layer ofcolor; a third layer of color; and playing lines.

Disclosed herein is an overlay system, comprising: a layer of seamingmaterial; a layer of geotextile fabric; a first adhesive layer appliedto the layer of geotextile fabric; a first infill layer comprising sand,rubber, or a rubber alternative, or a combination thereof adhered to thefirst adhesive layer; a second adhesive layer applied to the firstinfill layer; a second infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof adhered to the second adhesivelayer; a third adhesive layer adhered to the second infill layer; athird infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof adhered to the third adhesive layer; a fourthadhesive layer adhered to the third infill layer; a first layer of aresurfacer; a second layer of a resurfacer; a first layer of color; asecond layer of color; a third layer of color; and playing lines.

Disclosed herein is an overlay system, comprising: a layer of seamingmaterial; a layer of geotextile fabric; a first adhesive layer appliedto the layer of geotextile fabric; a first infill layer comprisingrubber or a combination of sand and rubber adhered to the first adhesivelayer; a second adhesive layer applied to the first infill layer; asecond infill layer comprising sand adhered to the second adhesivelayer; a third adhesive layer adhered to the second infill layer; athird infill layer comprising sand adhered to the third adhesive layer;a fourth adhesive layer adhered to the third infill layer; a first layerof a resurfacer; a second layer of a resurfacer; a first layer of acolor; a second layer of color; and playing lines. In an aspect of adisclosed overlay having at least 3 infill layers or 3 or more infilllayers, the layer of geotextile fabric can be partially adhered orsubstantially adhered to a substrate, or in an aspect, the layer ofgeotextile fabric can be positioned but not adhered over a substrate.

Components of the Disclosed Overlay Systems

Seaming Materials

In an aspect, one or more pieces of geotextile fabric can be seamedtogether to create a layer of geotextile fabric. In an aspect, thepieces of geotextile fabric can be seamed together by one or moreseaming materials. In an aspect, the seaming material can be applied tounderside of the layer of geotextile fabric. For example, the seamingmaterial can be applied to the surface of the geotextile fabric thatdirectly contacts the substrate. In an aspect, seaming material can beused wherever two separate pieces of geotextile fabric abut one another.In an aspect, the seaming material can overlap with each piece ofgeotextile fabric by about 3 inches to about 12 inches, or about 6inches to about 9 inches, or about 7 inches to about 8 inches. Thus, ifthe seaming material overlaps with each piece of geotextile fabric byabout 3 inches, then the width of the seaming material is about 6inches. Similarly, if the seaming material overlaps with each piece ofgeotextile fabric by about 6 inches, then the width of the seamingmaterial is about 12 inches. In an aspect, seaming material can be usedwherever two separate pieces of geotextile fabric abut one another. Inan aspect, the seaming material can overlap with each piece ofgeotextile fabric by at least 3 inches, by at least 6 inches, by atleast 9 inches, or by about 12 inches.

Seaming materials are known to the art and are commercially available.Commercially available seaming materials can include, but are notlimited to, woven and non-woven geotextile fabrics, carpet seamingtapes, Mylar®, and Tyvek. Mylar® is Dupont's registered trademark for aspecific family of products made from the resin polyethyleneterephthalate (PET). Mylar products commonly refer to polyester films orplastic films, which can be manufactured in a variety of differentcombinations of types, finishes, and thicknesses. In an aspect, seamingmaterial can be a self-adhered flashing such as Blueskin® Butyl Flash,which comprises a synthetic butyl compound, which is integrallylaminated to a white engineered polypropylene film surface. In anaspect, a self-adhered flashing can be specifically designed to beself-adhered to a substrate. If a seaming material is self-adhering,then it is not necessary to use apply an adhesive to the seamingmaterial prior to its contact with the layer of geotextile fabric.

Alternatively, in an aspect, one or more pieces of geotextile fabric canbe stitched together to create a seam. For example, in an aspect, thepieces of geotextile fabric can be stitched together using thread orfibers known to the art, including, but not limited to, polypropylene,polyester, fiberglass, or polyethylene threads or fibers.

In an aspect, a piece of fiberglass mesh can be applied to the top ofthe seam. In an aspect, the fiberglass mesh can be applied to the top ofthe seam prior to or during the application of the primer coat in abinder-based overlay system. In an aspect, the fiberglass mesh can beapplied to the top of the seam prior to or during the application of thefirst adhesive layer in an infill-based overlay system. Fiberglass meshcan strengthen the seamed geotextile fabric. See, e.g., layer (104) inFIG. 1 and (204) in FIG. 2.

Substrates

In an aspect, a substrate can be a newly installed substrate or anexisting substrate. In an aspect, a substrate can comprise a variety ofmaterials including, but not limited to, concrete, asphalt, gravel,clay, wood, or tile, or a combination thereof.

In an aspect, a disclosed overlay system can be substantially orpartially adhered to a substrate. In an aspect, a disclosed overlaysystem can be adhered to the substrate at the perimeter. For example, inan aspect, the overlay system can be adhered to the substrate byapplying an adhesive to one or more edges of the layer of geotextilefabric.

In an aspect, an adhesive can be non-continuously applied to one or moreedges of the layer of geotextile fabric. In an aspect, an adhesive canbe continuously applied to one or more edges of the layer of geotextilefabric. In an aspect, an adhesive can be non-continuously applied to theperimeter of the layer of geotextile fabric. In an aspect, an adhesivecan be continuously applied to the perimeter of the layer of geotextilefabric. See FIG. 4(B).

In an aspect, an adhesive can be non-continuously applied to apre-determined length of the perimeter of the layer of geotextilefabric. In other words, an adhesive can be applied to alternatingpre-determined lengths of the perimeter. For example, an adhesive can beapplied for to a pre-determined length of the perimeter of the layer ofgeotextile fabric and not applied to the immediately adjacentpre-determined length of the perimeter. Accordingly, an adhesive can beapplied to the entire perimeter of the layer in an alternating“on”/“off” pattern. See FIG. 4(A).

In an aspect, the pre-determined length can be about 6″ to about 24″ ofthe perimeter, about 10″ to about 20″ of the perimeter, or about 12″ toabout 18″ of the perimeter. In an aspect, the pre-determined length canbe about 6″, about 10″, about 12″, about 18″, or about 24″ of theperimeter. In an aspect, the pre-determined length can be about 12″,about 18″, or about 24″. In an aspect, the pre-determined length can beabout 12″. In an aspect, an adhesive can be applied for a pre-determinedwidth from one or more the edges of the layer of the geotextile fabrictowards the center of the layer. In an aspect, an adhesive can beapplied for a pre-determined width from the perimeter of the layer ofthe geotextile fabric towards the center of the layer. In an aspect, thepre-determined width can be about 3″ to about 30″, about 6″ to about27″, about 9″ to about 24″, about 12″ to about 21″, or about 15″ toabout 18″. In an aspect, the pre-determined width can be about 3″, about6″, about 10″, or about 12″. In an aspect, the pre-determined width canbe about 6″.

Primers

In an aspect, a disclosed overlay system can comprise one or more primerlayers. Primers are known to the art. For example, in an aspect, aprimer can be an acrylic primer or a non-acrylic primer. Acrylic primersinclude styrene acrylic primers. In an aspect, a primer can comprisestyrene acrylic. In an aspect, a disclosed overlay system can use apre-fabricated primer or a primer manufactured according to a series ofrequired or desired criteria. Pre-fabricated primers, which arecommercially available, include but are not limited to, primers such asElastoPrime™ Ultra-Maxx™, Drive-Maxx™, Climaseal™ Drive-Kote™Black-Maxx™, and Speed Coat™ (all manufactured by Blackjack®) andMasterseal Concentrate, which is a mineral filled asphalt emulsionpavement sealer (SealMaster®). In an aspect, the primer can beDrive-Maxx™.

Geotextile Fabrics

The disclosed overlay systems can comprise various geotextile fabrics.In an aspect, a geotextile fabric can be woven or non-woven. Woven andnon-woven fabrics are known to the art. Generally, woven and non-wovenfabrics can perform a variety of functions, including but not limitedto, drainage, separation, reinforcement, cushion, and filter. In anaspect, a geotextile fabric can be a fiberglass-reinforced geotextile.

Generally, woven geotextiles can be manufactured by weaving togethernarrow strips of film or threads (e.g., mono-filaments, multi-filamentsor fibrillated yarns). Woven geotextiles can be referred to by tensilestrength (i.e., the resistance a material has to breaking undertension). In an aspect, a woven geotextile can be relatively impermeableand can bear very high load capacity. Typically, woven geotextiles canhave a uniform appearance.

Generally, non-woven geotextiles can be manufactured by using syntheticfilaments or fibers that are continuously extruded and spun, blown, orplaced on a moving belt and then subjected to needle punching or heatbonded (rather than weaving). Non-woven fabrics can be referred to byweight (e.g., 3.4 ounces per square yard). In an aspect, a non-wovengeotextile can be used for separation, filtration, and drainagepurposes.

Table 1 provides a non-exhaustive summary of some of the characteristicsof both woven and non-woven geotextile fabrics.

TABLE 1 General Functions Performed by Woven and Non-Woven GeotextileFabrics Woven Geotextile Non-Woven Separation Separation ReinforcementFiltration High load capacity Drainage Referred to by Referred to byImpermeable Permeable Plastic-like Felt-like

In an aspect, geotextile fabric can comprise a roll of pre-fabricated ormanufactured geotextile fabric. As known to the art, a roll ofpre-fabricated or manufactured geotextile fabric facilitates ease ofinstallation and transport.

In an aspect, the layer of geotextile fabric comprises one or moreseparate pieces of geotextile fabric. In an aspect, the type of playingsurface can affect the size of the one or more pieces of geotextilefabric. For example, if the playing surface is a running track (e.g.,oval), then the size of the one or more pieces of geotextile fabric canbe longer than that of, for example, the size of the one or more piecesof geotextile fabric for a badminton court or a tennis court.

A piece of geotextile fabric can comprise any desired width. Forexample, a piece of geotextile fabric can comprise a width of about 1foot to about 30 feet. In an aspect, a piece of geotextile fabric cancomprise a width of about 1 foot to about 10 feet, about 10 feet toabout 20 feet, or about 20 feet to about 30 feet. In an aspect, a pieceof geotextile fabric can comprise a width of about 3 feet to about 12feet, about 12 feet to about 18 feet, or about 18 feet to about 30 feet.In an aspect, a piece of geotextile fabric can comprise a width of about12 feet or about 18 feet.

A piece of geotextile fabric can comprise any desired length. Forexample, a piece of geotextile fabric can comprise a length of about 1foot to about 500 feet. In an aspect, a piece of geotextile fabric cancomprise a length of about 1 foot to about 100 feet, about 100 feet toabout 200 feet, about 200 feet to about 300 feet, about 300 feet toabout 400 feet, or about 400 feet to about 500 feet. In an aspect, apiece of geotextile fabric can comprise a length of about 1 foot toabout 250 feet or about 250 feet to about 500 feet. In an aspect, apiece of geotextile fabric can comprise a length of about 100 feet,about 200 feet, about 300 feet, about 400 feet, or about 500 feet. In anaspect, a piece of geotextile fabric can comprise a length of about 200feet or about 400 feet.

In an aspect, a piece of geotextile fabric can comprise a width of about16 feet to about 18 feet and a length of about 320 feet to about 330feet. In an aspect, a piece of geotextile fabric can be about 17 feetand 4 inches in width and about 328 feet in length.

In an aspect, the layer of geotextile fabric comprises one or moreseparate pieces of geotextile fabric. In an aspect, the type of playingsurface can affect the size of the one or more pieces of geotextilefabric. For example, if the playing surface is a running track (e.g.,oval), then the size of the one or more pieces of geotextile fabric canbe longer than that of, for example, the size of the one or more piecesof geotextile fabric for a badminton court or a tennis court.

In an aspect, geotextile fabric can comprise a roll of geotextilefabric. As known to the art, a roll of material facilitates ease ofinstallation and transport.

In an aspect of a disclosed overlay, the layer of geotextile fabric canbe partially or substantially adhered to a substrate. In an aspect of adisclosed overlay, the layer of geotextile fabric can be positioned butnot adhered over a substrate.

In an aspect, a disclosed overlay system can use a pre-fabricatedgeotextile fabric or a geotextile fabric manufactured according to aseries of required or desired criteria.

Pre-Fabricated Geotextile Fabrics

Geotextile fabrics are known to the art. In an aspect, a disclosedoverlay system can use a pre-fabricated, which are commerciallyavailable, geotextile fabric. For example, in an aspect, pre-fabricatedgeotextile fabrics include, but are not limited to, commerciallyavailable geotextile fabrics such as Rock Pec® (TenCate), ACECompo™ GS(ACE Geosynthetics), and ACECompo™ PETB (ACE Geosynthetics). Rock Pec isa biaxial geo-composite composed of polyester fibers. ACECompo GS ispolyester or polypropylene nonwoven geotextile comprising glass-fiberyarns and ACECompo PETB is a knitted composite comprising nonwovengeotextile with unilateral or bilateral polyester yarns.

In an aspect, pre-fabricated geotextile fabrics include, but are notlimited to, commercially the family of commercially available geotextilefabrics known as Mirafi® (TenCate). For example, MPG and MPG4 are glassfilament reinforced paving composites comprised of fiberglass filamentyarn incorporated into a nonwoven polypropylene paving fabric. MPGcomposites combine the excellent reinforcing properties of glassfilaments with optimum liquid asphalt retention capacity of amechanically bonded AASHTO nonwoven paving fabric. For example, theN-Series are nonwoven polypropylene geotextiles comprising staplefibers, which combine high durability, high water flow rates, anddurability. The S-Series are nonwoven polypropylene geotextilescomprising staple fibers, which provide exceptional results due to hightensile strengths and tremendous physical and hydraulic properties. TheRSi Series Woven Geosynthetics are used for varying application needsincluding: base course reinforcement and subgrade stabilization forroad, runway and railway construction; embankment stabilization on softfoundations; reinforcement for mechanically stabilized earth (MSE)structures; liner support, voids bridging, reinforcement over softhazardous pond closures and other environmental market applications.When superior performance, flexibility, and versatility are necessary,the H2Ri-Series makes the difference for varying application needsincluding: base course reinforcement and subgrade stabilization forroad, runway and railway construction; frost heave/frost boils;embankment stabilization on soft foundations; reinforcement formechanically stabilized earth (MSE) structures; liner support, voidsbridging, reinforcement over soft hazardous pond closures and otherenvironmental market applications. The HP-Series high performancegeotextiles are used for base course reinforcement and soilstabilization/reinforcement applications. The HP-Series Geotextiles arespecifically designed to provide separation, filtration, andreinforcement for moderate to severe site condition. These geotextilesare extremely versatile, ensuring long-term performance in new roadwayconstruction. The PET-Series woven high-strength polyester geotextilesare used to provide stability and limit differential settlement whenconstructing embankments over soft soils. The PET-Series geotextilesprovide the highest tensile and long term design strength (LTDS)available in any geosynthetic. The PET-Series are comprised of hightenacity and high molecular weight polyester yarns which provideexcellent creep resistance, strength, and soil interaction. TheFW-Series geotextiles are made of highly UV stabilized monofilament andmultifilament yarns that possess unique physical and hydraulicproperties not found in other woven or nonwoven geotextiles. With highlydurable strengths, consistent pore sizes, high flow rates, and clogresistance, this product is perfect for shorelines and other erosioncontrol applications. The FW-Series geotextiles are used underneath riprap or concrete revetment systems along inland waterways and coastalshorelines to protect spillways and cut-off drains.

Manufactured Geotextile Fabrics

In an aspect, geotextile fabrics that can be employed in the systems andmethods disclosed herein include geotextile fabrics that aremanufactured according to a series of required or desired criteria. Forexample, in an aspect, a disclosed overlay can require the de novomanufacture of a geotextile fabric having specific mechanicalproperties. Accordingly, methods of manufacturing geotextile fabrics areknown to the art.

In an aspect, a geotextile fabric for use in the disclosed systems andmethods can be characterized by one or more mechanical properties. Forexample, a geotextile fabric can be characterized by tensile strength.In an aspect, tensile strength can be measured according to machinedirection (MD). In aspect, the MD tensile strength of a geotextilefabric can be about 38 kN/m to about 102 kN/m, about 38 kN/m to about 44kN/m, about 53 kN/m to about 60 kN/m, about 73 kN/m to about 81 kN/m, orabout 93 kN/m to about 102 kN/m. In an aspect, tensile strength can bemeasured according to cross direction (CD). In aspect, the CD tensilestrength of a geotextile fabric can be about 38 kN/m to about 102 kN/m,about 38 kN/m to about 44 kN/m, about 48 kN/m to about 55 kN/m, about 73kN/m to about 81 kN/m, or about 93 kN/m to about 102 kN/m. In an aspect,the geotextile fabric can have a MD tensile strength of about 38 toabout 44 kN/m and a CD tensile strength of about 38 to about 44 kN/m, aMD tensile strength of about 53 to about 60 kN/m and a CD tensilestrength of about 48 to about 55 kN/m, a MD tensile strength of about 73to about 81 kN/m and a CD tensile strength of about 73 to about 81 kN/m,or a MD tensile strength of about 93 to about 102 kN/m and a CD tensilestrength of about 93 to about 102 kN/m.

In an aspect, the tensile strength (MD and CD) at 2% can be about 6 kN/mto about 22 kN/m. In an aspect, the tensile strength (MD and CD) at 2%can be about 6 kN/m to about 10 kN/m, about 10 kN/m to about 14 kN/m,about 14 kN/m to about 18 kN/m, or about 18 kN/m to about 22 kN/m. In anaspect, the tensile strength (MD and CD) at 2% can be about 8 kN/m,about 12 kN/m, about 16 kN/m, or about 20 kN/m.

In an aspect, the tensile strength (MD and CD) at 3% can be about 10kN/m to about 29 kN/m. In an aspect, the tensile strength (MD and CD) at3% can be about 10 kN/m to about 14 kN/m, about 14 kN/m to about 18kN/m, about 20 kN/m to about 24 kN/m, or about 25 kN/m to about 29 kN/m.In an aspect, the tensile strength (MD and CD) at 3% can be about 12kN/m, about 16 kN/m, about 22 kN/m, or about 27 kN/m.

In an aspect, the tensile strength (MD and CD) at 5% can be about 16kN/m to about 48 kN/m. In an aspect, the tensile strength (MD and CD) at5% can be about 16 kN/m to about 20 kN/m, about 20 kN/m to about 24kN/m, about 35 kN/m to about 39 kN/m, or about 44 kN/m to about 48 kN/m.In an aspect, the tensile strength (MD and CD) at 5% can be about 18kN/m, about 22 kN/m, about 37 kN/m, or about 46 kN/m.

For example, in an aspect, a geotextile fabric can comprise glassfilaments in an amount of about 65% by weight to about 80% by weight. Inan aspect, a geotextile fabric can comprise glass filament in an amountof about 76% by weight to about 78% by weight. In an aspect, ageotextile fabric can comprise glass filament in an amount of about 77%by weight. In an aspect, the glass filaments of a disclosed geotextilefabric can have a tensile strength at 0° of 655 lbs/in as measured byASTM D6637. In an aspect, the glass filaments in a disclosed geotextilefabric can have a tensile strength at 90° of 655 kN/m. In an aspect, ageotextile fabric having glass filaments can have a tensile elongationof less than 3%. In an aspect, a geotextile fabric having glassfilaments that are temperature resistance, as measured by ASTM D276, ofabout 752° F. or about 400° C.

In an aspect, the geotextile fabric can comprise polyester or fiberglassyarns or glass filaments. In an aspect, the polyester or fiberglassyarns or glass filaments can be sewn to the upper surface of thegeotextile fabric. The polyester or fiberglass yarns or glass filamentscan comprise a vertical height of about 1/16″ to about ½″. In an aspect,the polyester or fiberglass yarns or glass filaments can be bi-axiallyarranged. The biaxial arrangement of yarns or glass filaments cangenerate a grid of squares. For example, the squares can comprise awidth of about ½″ to about 3″, a length of about ½″ to about 3″, or acombination thereof.

In an aspect, the presence of polyester or fiberglass yarns or glassfilaments in the geotextile fabric provide a surprising degree ofstructural stability to the overlay systems disclosed herein. Thisstructural stability was previously unknown to the art. Specifically,these yarns or filaments provide an irregular surface upon which anadhesive can be applied. Such an irregular surface provides a strongerbond between the adhesive and the geotextile fabric than that previouslyknown in the art. This is an advantage over traditional overlay systems,which fail to provide structural reinforcement to the top of theoverlay. For example, one of the traditional overlay systems simply usesa non-woven fabric that is adhered to substrate and topped with acryliccolor coatings. The horizontal tear strength of this traditional overlaysystem is determined only by the strength of the non-woven material. Ifthe substrate moves or fluctuates with temperature, for example, themovement or fluctuation of the substrate will cause tears and contractsin the surface of the overlay.

In an aspect, a grid configuration of polyester or fiberglass yarns orglass filaments can also confer one or more advantages to the geotextilefabric. For example, in an aspect, the grid formation of polyester orfiberglass yarns or glass filaments can provide superior stability foran infill layer, can provide horizontal tensile strength for thegeotextile fabric, and can provide biaxial strength to the geotextile.

Infills

In an aspect, a disclosed overlay system can comprise one or more infilllayers. In an aspect, an infill layer can comprise sand, rubber, or arubber alternative, or a combination thereof. In an aspect, sand can besilica sand. As known to the art, silica sand is renowned for quality,uniformity, and consistency. In an aspect, silica sand can be 50-80 meshsilica sand. As known to the art, rubber can be crumb rubber, which istypically recycled rubber product generated from tires. In an aspect, aninfill layer can comprise a rubber alternative. The art is familiar withrubber alternatives, including but not limited to, Nike grind, coatedrubber, styrene butadiene rubber (SBR), ethylene propylene diene monomer(EPDM), thermoplastic polyurethane (TPU), and thermoplastic elastomer(TPE).

In an aspect, a disclosed system can comprise at least one infill layer.In an aspect, a disclosed system can comprise a first infill layercomprising sand. In an aspect, a disclosed system can comprise a firstinfill layer comprising rubber or a combination of rubber and sand(e.g., crumb rubber and silica sand). In an aspect, a disclosed systemcan comprise a first infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof.

In an aspect, a disclosed system can comprise two infill layers. In anaspect, a disclosed system can comprise at least two infill layers. Inan aspect, a disclosed system can comprise a first infill layercomprising sand (e.g., silica sand) and a second infill layer comprisingsand (e.g., silica sand). In an aspect, a disclosed system can comprisea first infill layer comprising rubber or a combination of rubber andsand (e.g., crumb rubber and silica sand) and a second infill layercomprising sand (e.g., silica sand). In an aspect, a disclosed systemcan comprise a first infill layer comprising sand, rubber, a rubberalternative, or a combination of thereof and a second infill layercomprising sand, rubber, a rubber alternative, or a combination thereof.In an aspect, the infill layers can be the same as one another or theinfill layers can be different from one another.

In an aspect, a disclosed system can comprise three infill layers. In anaspect, a disclosed system can comprise at least three infill layers. Inan aspect, a disclosed system can comprise a first infill layercomprising rubber or a combination of rubber and sand (e.g., crumbrubber and silica sand), a second infill layer comprising sand (e.g.,silica sand), and a third infill layer comprising sand (e.g., silicasand). In an aspect, a disclosed system can comprise a first infilllayer comprising sand, rubber, or a combination of sand and rubber, asecond infill layer comprising sand, rubber, or a combination of sandand rubber, and a third infill layer comprising sand, rubber, or acombination of sand and rubber. In an aspect, the infill layers can bethe same as one another, or the infill layers can be different from oneanother, or one or more of the infill layers can be the same while oneor more of the infill layers can be different.

In an aspect, a disclosed overlay system comprising a first infill layer(e.g., rubber, silica sand, or a combination thereof) can comprise oneor more additional infill layers. In an aspect, any additional infilllayer can be sand (e.g., silica sand), rubber (e.g., crumb rubber), arubber alternative, or a combination thereof (e.g., crumb rubber andsilica sand).

In an aspect, any disclosed infill layer can also comprise cement. Theskilled person can ascertain the climate conditions requiring the use ofcement. In an aspect, a disclosed infill layer can comprise rubber andcement. In an aspect, an disclosed infill layer can comprise sand andcement. In an aspect, a disclosed infill layer can comprise sand,rubber, and cement. In an aspect, a disclosed infill layer can comprisesand, rubber, or cement, or any combination thereof. For example, in anaspect of disclosed infill based overlay system, one or more infilllayer can comprise silica sand, crumb rubber, and cement. In an aspect,a disclosed infill layer can comprise one or more additional substances,including but not limited to, emulsifiers and adhesives.

In an aspect, a disclosed overlay system can be used to effect a“cushioned court” system. For example, each of the infill layers cancomprise a customizable amount of sand, rubber, or rubber alternative,or a combination thereof. For example, a “cushioned court” system cancomprise a first infill layer comprising rubber or rubber alternative orrubber or rubber alternative and sand. In an aspect, a “cushioned court”system can also comprise one or more additional infill layers comprisingsand, rubber, or a rubber alternative, or a combination thereof. In anaspect, if a softer surface is desired, then the one or more binderlayers can contain more rubber or rubber alternative than sand. In anaspect, if a softer surface is desired, then the one or more infilllayers can contain only rubber or rubber alternative and no sand.

In an aspect, a disclosed overlay system can be used to effect a “hardcourt” system. For example, a “hard court” system can comprise an infilllayer comprising sand. In an aspect, a “hard court” system can alsocomprise one or more additional infill layers comprising sand. In anaspect, if a harder surface is desired, then the one or more infilllayers can contain more sand than rubber or rubber alternative. In anaspect, if a harder surface is desired, then the one or more infilllayers can contain only sand and no rubber or rubber alternative.

Binders

In an aspect, a disclosed overlay system can comprise one or more binderlayers. In an aspect, a binder can be manufactured in view of theproperties of the geotextile fabric of the disclosed overlay system. Asrecognized by the skilled person, a binder can be manufactured accordingto a series of required or desired criteria. Specific criteria formanufacturing a binder can include, for example, but are not limited to,the amount of a reactive solid in the binder, the density of the binder,the pH of the binder, the viscosity of the binder, the glass transitiontemperature (Tg) of the binder, the minimum film forming temperature(MFFT) of the binder, the particle size of the solid contents of thebinder, and the particle charges of the solid contents.

As known in the art, the minimum film forming temperature (MFFT) is thelowest temperature at which a latex, emulsion, or adhesive willuniformly coalesce when laid on a substrate as a thin film. An accurateMFFT value allows the formulation of products that cure correctly underspecified application conditions. As known in the art, the glasstransition temperature (Tg) is the temperature range where athermosetting polymer changes from a hard, rigid, or “glassy” state to amore pliable, compliant, or “rubbery” state.

In an aspect, a disclosed binder can comprise a reactive solid in anamount of between about 20% by weight and about 90% by weight, or about30% by weight and about 80% by weight, or about 40% by weight and about70% by weight, or about 50% by weight and about 60% by weight. Solidcontents are reactive solids. Reactive solids can include, but are notlimited to, polyvinyl acetate, latex, styrene butadiene resin, styreneacrylic, styrene acrylic resin, 100% acrylic resin, epoxy ester, oilbase (long, short, medium oil alkyds), polyurethane oil base, siliconeresin base, silane resin base, silicates, self-dissolvable MMA monomerbeads, peroxide initiated MMA monomers, polyurethane prepolymer, epoxyurethane, acrylate epoxy, and UV cured based materials. In an aspect, areactive solid can be styrene acrylic.

In an aspect, a disclosed binder can comprise a density of about 6 lbper gallon to about 18 lb per gallon, or about 7 lb per gallon to about17 lb per gallon, or about 8 lb per gallon to about 16 lb per gallon, orabout 9 lb per gallon to about 15 lb per gallon, or about 10 lb pergallon to about 14 lb per gallon, or about 11 lb per gallon to about 13lb per gallon, or about 12 lb per gallon. In an aspect, a disclosedbinder can comprise a density of about 9 lb per gallon to about 15 lbper gallon

In an aspect, a disclosed binder can comprise a pH of about 3 to a pH ofabout 11, a pH of about 4 to a pH of about 10, a pH of about 5 to a pHof about 9, a pH of about 6 to a pH of about 8, or a pH of about 7. Inan aspect, a disclosed binder can a pH of about 5 to a pH of about 9.

In an aspect, a disclosed binder can comprise a viscosity of about10,000 centipose to about 60,000 centipose, or about 11,000 centipose toabout 55,000 centipose, or about 12,000 centipose to about 50,000centipose, or about 13,000 centipose to about 45,000 centipose, or about14,000 centipose to about 40,000 centipose. In an aspect, a disclosedbinder can comprise a viscosity of about 12,000 centipose to about50,000 centipose.

In an aspect, a disclosed binder can comprise a Tg of about −50° C. toabout 50° C., or about −40° C. to about 40° C., or about −30° C. toabout 30° C., or about −20° C. to about 20° C., or about −10° C. toabout 10° C., or about 0° C. In an aspect, a low Tg can help the binderretain a “tacky-ness”, which can prevent paint from peeling off theoverlay system. In an aspect, the binder can comprise low Tg 100%acrylic. In an aspect, a disclosed binder can comprise a Tg of about−30° C. to about 30° C.

In an aspect, a disclosed binder can comprise a MFFT of about −20° C. toabout 40° C., or about −10° C. to about 30° C., or about 0° C. to about20° C., or about 10° C. In an aspect, a disclosed binder can comprise aMFFT of about 0° C. to about 20° C.

In an aspect, a disclosed binder can comprise a reactive solid havingparticles sizes of about 0.01 μm to about 12.0 μm, or about 0.02 μm toabout 11.0 μm, or about 0.03 μm to about 10.0 μm, or about 0.04 μm toabout 9.0 μm, or about 0.05 μm to about 8.0 μm, or about 0.06 μm toabout 7.0 μm. In an aspect, a disclosed binder can comprise a reactivesolid having particles sizes of about 0.03 μm to about 10.0 μm.

In an aspect, a disclosed binder can comprise a reactive solid havinganionic particle charges, cationic particle charges, or both anionic andcationic particle charges.

In an aspect, the skilled person can evaluate the disclosed criteria forpreparing a disclosed binder. For example, when preparing a disclosedbinder for use with a specific geotextile fabric, the skilled person canascertain which reactive solid to use as well as the amount of thereactive solid to use. When preparing a disclosed binder for use with aspecific geotextile fabric, the skilled person can ascertain thepreferred density of the binder, the optimal density of the binder, theresulting density of the binder, or a combination thereof. Whenpreparing a disclosed binder for use with a specific geotextile fabric,the skilled person can ascertain the preferred viscosity of the binder,the optimal viscosity of the binder, the resulting viscosity of thebinder, or a combination thereof. When preparing a disclosed binder foruse with a specific geotextile fabric, the skilled person can ascertainthe preferred Tg of the binder, the optimal Tg of the binder, theresulting Tg of the binder, or a combination thereof. When preparing adisclosed binder for use with a specific geotextile fabric, the skilledperson can ascertain the preferred MFFT of the binder, the optimal MFFTof the binder, the resulting MFFT of the binder, or a combinationthereof. When preparing a disclosed binder for use with a specificgeotextile fabric, the skilled person can ascertain the preferredparticle size of a reactive solid, the optimal particle size of areactive solid, the resulting particle size of a reactive solid, or acombination thereof. When preparing a disclosed binder for use with aspecific geotextile fabric, the skilled person can ascertain thepreferred particle charges of a reactive solid, the optimal particlecharges of a reactive solid, the resulting particle charges of areactive solid, or a combination thereof.

In an aspect, a binder can comprise about 30% by weight to about 80% byweight of an acrylic having a particle size of about 0.03 μm to about 10μm and having particles that are anionic or cationic, a density of about9 lb per gallons to about 15 lb per gallons, a pH of about 5 to about 9,a viscosity of about 12,000 centipose to about 50,000 centipose, a Tg ofabout −30° C. to 30° C., a MFFT of about 0° C. to about 20° C.

In an aspect, a binder can comprise about 30% by weight of styreneacrylic having a particle size of about 0.03 μm to about 10 μm andhaving particles that are anionic or cationic, a density of about 9 lbper gallons to about 15 lb per gallons, a pH of about 5 to about 9, aviscosity of about 12,000 centipose to about 50,000 centipose, a Tg ofabout −30° C. to 30° C., a MFFT of about 0° C. to about 20° C.

In an aspect, a disclosed overlay system can comprise at least onebinder layer. In an aspect, a disclosed system can comprise between 1-10binder layers, between 2-9 binder layers, between 3-8 binder layers,between 4-7 binder layers, or between 5-6 binder layers. In an aspect, adisclosed overlay system can comprise 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10binder layers.

In an aspect, a disclosed overlay system can comprise one or more binderlayers, each binder layer being the same as the other binder layers. Inan aspect, a disclosed overlay system can comprise one or more binderlayers, each binder layer being different than the other binder layers.In an aspect, a disclosed overlay system can comprise one or more binderlayers, some binder layers being the same while other binder layersbeing different. For example, if an overlay system comprises 6 binderlayers, then in an aspect, binder layers 1-2 (which are the same as oneanother) can be different than binder layers 3-4 (which are the same asone another), which can be different than binder layers 5-6 (which arethe same as one another). In an aspect, each binder layer can differfrom every other binder layer.

In an aspect of a disclosed overlay system, a binder layer can comprisesand, rubber, a rubber alternative, or a combination thereof. In anaspect, sand can be silica sand. As known to the art, silica sand isrenowned for quality, uniformity, and consistency. In an aspect, silicasand can be 50-80 mesh silica sand. As known to the art, rubber can becrumb rubber, which is typically recycled rubber product generated fromtires. In an aspect, an infill layer can comprise a rubber alternative.The art is familiar with rubber alternatives, including, but not limitedto, Nike grind, coated rubber, styrene butadiene rubber (SBR), ethylenepropylene diene monomer (EPDM), thermoplastic polyurethane (TPU), andthermoplastic elastomer (TPE).

In an aspect, for example, a first binder layer can comprise more rubberor rubber alternative than subsequent binder layers. In an aspect, alast binder layer can comprise more sand than previous binder layers. Inan aspect, to achieve a desired degree of cushion, each binder layer ofa disclosed overlay system can be customized. For example, in an aspect,each of the one or more binder layers can comprise a customizable amountof sand, rubber, or rubber alternative, or a combination thereof. Theability to customize the content of the binder layer confers designflexibility to the overlay system, and distinguishes the disclosedoverlay system from other, inferior systems. For example, if a hardersurface is desired, then the one or more binder layers can contain moresand than rubber or rubber alternative. If a softer surface is desired,then the one or more binder layers can contain more rubber or rubberalternative than sand. In an aspect, as the number of binder layersincreases, the amount of rubber or rubber alternative in each of thosebinder layers can decrease. In other words, there can be an inverserelationship between the number of the binder layer in the sequence ofbinder layers and the amount of rubber or rubber alternative in thatbinder layer. The earlier applied binder layers (e.g., layers 1-2) canhave more rubber or rubber alternative than sand or can have all rubberor rubber alternative (e.g., no sand) while the later applied binderlayers (e.g., layers 7-8) can have less rubber or rubber alternative orno rubber or rubber alternative (e.g., no rubber).

To ensure customizability, a binder layer can comprise 1-5 parts binderand 1-5 parts sand, rubber, or rubber alternative, or a combinationthereof. In an aspect, a binder layer can comprise 2 parts binder and 1part sand, rubber, or rubber alternative, or a combination thereof. Inan aspect, a binder layer can be 2 parts binder and 1 part sand. In anaspect, a binder layer can be 2 parts binder and 1 part rubber. In anaspect, a binder layer can be 2 parts binder and 1 part rubberalternative. In an aspect, a binder layer can be 2 parts binder and 1part the combination of sand and rubber. In an aspect, a binder layercan be 2 parts binder and 1 part the combination of sand and rubberalternative. In an aspect, concrete can be added to disclosed binderlayer. The skilled person can determine how much concrete to add to adisclosed binder layer to achieve the desired performance of the binderlayer. In an aspect, water can be added to disclosed binder layer. Theskilled person can determine how much water to add to a disclosed binderlayer to achieve the desired performance of the binder layer. As thedisclosed overlays can be cast-in-place, the binder layers can beprepared at the time of application.

Adhesives

In an aspect, a disclosed overlay system can comprise one or moreadhesive layers. For example, in an aspect, an adhesive layer can beapplied to an infill layer, or to a seaming material, or to a substrate,or to a layer of geotextile fabric, or a combination thereof. In anaspect, a disclosed overlay system can comprise an adhesive layerbetween one or more layers to be adhered. In an aspect, a disclosedadhesive can comprise a water-based adhesive or an oil-based adhesive.

In an aspect, a disclosed adhesive can comprise a liquid polymer. Liquidpolymers are known to the art and are commercially available. In anaspect, a polymer can be a carboxylated styrene-butadiene emulsion thatcan adhere to many types of substrates (e.g., Rovene® 4125 (MallardCreek Polymers)). In an aspect, a polymer can be a self-crosslinkingcarboxylated styrene-butadiene emulsion that can adhere to many types ofsubstrates (e.g., Rovene® 4170 (Mallard Creek Polymers)). In an aspect,an adhesive can comprise a polyurethane construction adhesive.Polyurethane construction adhesives are known to the art. In an aspect,a polyurethane construction adhesive can be water-resistant andweather-resistant, can set in about 30 minutes, can fully cure in about24 hours, or a combination thereof.

In an aspect, a disclosed liquid polymer can be applied according to amethod known to the art, such as, for example, but not limited to, apneumatic sprayer.

Resurfacers

In an aspect, a disclosed overlay system can comprise one or more layersof a resurfacer. For example, a resurfacer can be an acrylic resurfaceror a non-acrylic resurfacer. A resurfacer can be water-resistant. In anaspect, a disclosed resurfacer can be an acrylic-based emulsion, whichcan be combined with silica sand or water or both. Resurfacers are knownto the art and are commercially available. For example, a commerciallyavailable acrylic resurfacer is NovaSurface (NovaSports USA). Othercommercial manufacturers of acrylic resurfacer include SportMaster,Laykold, California Products, and World Class Paints.

In an aspect, a resurfacer can be used to fill in any smallirregularities that exist in the overlay following the installation ofthe one or more binder layers. For example, in an aspect, a disclosedoverlay system can comprise one layer of a resurfacer, two layers of aresurfacer, three layers of a resurfacer, or more than 3 layers of aresurfacer. In an aspect, a disclosed overlay system can comprise one ormore layers, two or more layers, three or more layers of an acrylicresurfacer.

Colors

In an aspect, a disclosed overlay system can comprise one or more layersof color. For example, a color can be an acrylic color or a non-acryliccolor. In an aspect, color can be any acrylic or non-acrylic color ofinterest. For example, the acrylic or non-acrylic color can be green fortennis court. For example, a disclosed overlay system can comprise onelayer of color, two layers of color, three layers of acrylic color, ormore than 3 layers of color. For example, a disclosed overlay system cancomprise one layer of acrylic color, two layers of acrylic color, threelayers of acrylic color, or more than 3 layers of acrylic color.

Playing Lines

In an aspect, a disclosed overlay system can comprise playing lines. Inan aspect, an overlay system can comprise playing lines for a tenniscourt, a pickle ball court, a basketball court, a track (e.g., an oblongrunning track), a volleyball court, a racquet ball court, or a badmintoncourt, or some other athletic playing surface. Playing lines anddimensions for a tennis court, a pickleball court, and a basketballcourt are known to those skilled in the art. Representative examples areprovided in the figures of the provisional patent application(62/431,955) to which the present application claims the benefit ofpriority, which is incorporated by reference in its entirety.

Methods

Disclosed herein are methods of installing a binder-based overlay systemand methods of installing a non-binder-based overlay system.

Methods of Installing a Binder-Based Overlay System

Disclosed herein are methods of installing binder-based overlay systems.

Disclosed herein is a method of installing a binder-based overlay systemcomprising correcting one or more deformations in the existingsubstrate; contacting a layer of geotextile fabric to a surface of asubstrate; applying one or more primer layers to a surface of thegeotextile fabric; adding one or more binder layers; applying two ormore resurfacer layers; applying two or more color layers; and providingplaying lines on the surface of the overlay.

Disclosed herein is a method of installing a binder-based overlay systemcomprising contacting a layer of geotextile fabric to a surface of asubstrate; applying one or more primer layers to a surface of thegeotextile fabric; adding one or more binder layers; applying two ormore resurfacer layers; applying two or more color layers; and providingplaying lines on the surface of the overlay.

Disclosed herein is a method of installing a binder-based overlay systemcomprising correcting one or more deformations in the existingsubstrate; contacting a layer of geotextile fabric to a surface of asubstrate; applying one or more primer layers to a surface of thegeotextile fabric; adding one or more binder layers to the one or moreprimer layers; applying two or more resurfacer layers to the one or morebinder layers; applying two or more color layers to the two or moreresurfacer layers; and providing playing lines on the surface of theoverlay.

Disclosed herein is a method of installing a binder-based overlay systemcomprising contacting a layer of geotextile fabric to a surface of asubstrate; applying one or more primer layers to a surface of thegeotextile fabric; adding one or more binder layers to the one or moreprimer layers; applying two or more resurfacer layers to the one or morebinder layers; applying two or more color layers to the two or moreresurfacer layers; and providing playing lines on the surface of theoverlay.

Disclosed herein is a method of installing a binder-based overlay systemcomprising: correcting one or more deformations in the existingsubstrate; contacting a layer of geotextile fabric to a surface of asubstrate; applying one or more primer layers to a surface of thegeotextile fabric; adding one or more binder layers to the one or moreprimer layers; applying one or more resurfacer layers to the one or morebinder layers; applying one or more color layers to the one or moreresurfacer layers; and providing playing lines on the surface of theoverlay.

Disclosed herein is a method of installing a binder-based overlay systemcomprising contacting a layer of geotextile fabric to a surface of asubstrate; applying one or more primer layers to a surface of thegeotextile fabric; adding one or more binder layers to the one or moreprimer layers; applying one or more resurfacer layers to the one or morebinder layers; applying one or more color layers to the one or moreresurfacer layers; and providing playing lines on the surface of theoverlay.

Disclosed herein is a method of installing a binder-based overlay systemcomprising correcting one or more deformations in the existingsubstrate; contacting a layer of geotextile fabric to a surface of asubstrate; applying one or more primer layers to a surface of thegeotextile fabric; adding one or more binder layers; applying one ormore resurfacer layers; applying one or more color layers; and providingplaying lines on the surface of the overlay.

Disclosed herein is method of installing a binder-based overlay systemcomprising contacting a layer of geotextile fabric to a surface of asubstrate; applying one or more primer layers to a surface of thegeotextile fabric; adding one or more binder layers; applying one ormore resurfacer layers; applying one or more color layers; and providingplaying lines on the surface of the overlay.

Disclosed herein is a method of installing a binder-based overlay systemcomprising partially or substantially adhering a layer of geotextilefabric to the surface of a substrate; applying a primer layer; andadding one or more binder layers.

Disclosed herein is a method of installing a binder-based overlaysystem, comprising: correcting one or more deformations in an existingsubstrate; partially or substantially adhering a layer of geotextilefabric to the surface of a substrate; applying a primer layer; andadding one or more binder layers.

Disclosed herein is a method of installing a binder-based overlay systemcomprising correcting one or more deformations in the substrate;partially or substantially adhering two or more pieces of geotextilefabric to the substrate; seaming two or more pieces of geotextile fabricto the substrate to create a layer of seamed geotextile fabric; applyingone or more primer layers; adding one or more binder layers; applyingone or more resurfacer layers; applying one or more color layers; andproviding playing lines on the surface of the overlay.

Methods of Installing an Infill-Based Overlay System

Disclosed herein are methods for installing infill-based overlaysystems. Disclosed herein are methods for installing infill-basedoverlay systems that can be used indoors or outdoors. In an aspect, adisclosed method on installing an infill-based overlay system can beused to provide a variety of athletic playing surfaces. For example, inan aspect, an infill-based overlay system can be used to provide anindoor or an outdoor tennis court, a pickle ball court, a basketballcourt, a track (e.g., an oblong running track), a racquet ball court, avolleyball court, or a badminton court.

1. Infill Layer

Disclosed herein a method of installing an infill-based overlay system,comprising: contacting a layer of geotextile fabric to the surface of asubstrate; applying an adhesive to a surface of the geotextile fabric;and adding an infill layer to the adhesive layer.

Disclosed herein a method of installing an infill-based overlay system,comprising: contacting a layer of geotextile fabric to the surface of asubstrate; applying one or more layers of adhesives; and adding one ormore infill layers.

Disclosed herein a method of installing an infill-based overlay system,comprising: contacting a layer of geotextile fabric to the surface of asubstrate; applying an adhesive to a surface of the geotextile fabric;and adding an infill layer comprising sand, rubber, or a combination ofsand and rubber to the adhesive layer.

Disclosed herein a method of installing an infill-based overlay system,comprising: contacting a layer of geotextile fabric to the surface of asubstrate; applying one or more layers of adhesives; and adding one ormore infill layers comprising sand, rubber, or a combination of sand andrubber.

Disclosed herein a method of installing an infill-based overlay system,comprising: correcting one or more deformations in the existingsubstrate; contacting a layer of geotextile fabric to the surface of asubstrate; applying an adhesive to a surface of the geotextile fabric;adding an infill layer to the adhesive layer.

Disclosed herein a method of installing an infill-based overlay system,comprising: correcting one or more deformations in the existingsubstrate; contacting a layer of geotextile fabric to the surface of asubstrate; applying an adhesive to a surface of the geotextile fabric;adding an infill layer comprising sand, rubber, or a rubber alternative,or a combination thereof to the adhesive layer.

Disclosed herein a method of installing an infill-based overlay system,comprising: correcting one or more deformations in the existingsubstrate; contacting a layer of geotextile fabric to the surface of asubstrate; applying one or more layers of adhesives; and adding one ormore infill layers comprising sand, rubber, or a rubber alternative, ora combination thereof.

Disclosed herein a method of installing an infill-based overlay system,comprising: correcting one or more deformations in the existingsubstrate; contacting a layer of geotextile fabric to the surface of asubstrate; applying one or more layers of adhesives; and adding one ormore infill layers comprising sand, rubber, or a rubber alternative, ora combination thereof.

Disclosed herein a method of installing an infill-based overlay system,comprising: contacting a layer of geotextile fabric to the surface of asubstrate; applying a first adhesive layer to the surface of thegeotextile fabric; adding an infill layer comprising sand, rubber, or arubber alternative, or a combination thereof to the first adhesivelayer; applying a second adhesive to the infill layer; applying at leastone layer of a resurfacer; and providing playing lines on the surface ofthe overlay.

Disclosed herein a method of installing an infill-based overlay system,comprising: contacting a layer of geotextile fabric to the surface of asubstrate; applying a first adhesive layer to the surface of thegeotextile fabric; adding an infill layer comprising sand, rubber, or arubber alternative, or a combination thereof to the first adhesivelayer; applying a second adhesive to the infill layer; applying a firstlayer of a resurfacer; applying a second layer of a resurfacer; andproviding playing lines on the surface of the overlay.

Disclosed herein a method of installing an infill-based overlay system,comprising: contacting a layer of geotextile fabric to the surface of asubstrate; applying a first adhesive layer to the surface of thegeotextile fabric; adding an infill layer comprising sand, rubber, or arubber alternative, or a combination thereof to the first adhesivelayer; applying a second adhesive to the infill layer; applying a firstlayer of a resurfacer; applying a second layer of a resurfacer; applyingat least one layer of color; and providing playing lines on the surfaceof the overlay.

Disclosed herein a method of installing an infill-based overlay system,comprising: contacting a layer of geotextile fabric to the surface of asubstrate; applying a first adhesive layer to the surface of thegeotextile fabric; adding an infill layer comprising sand, rubber, or arubber alternative, or a combination thereof to the first adhesivelayer; applying a second adhesive to the infill layer; applying a firstlayer of a resurfacer; applying a second layer of resurfacer; applying afirst layer of color; applying a second layer of color; and providingplaying lines on the surface of the overlay.

Disclosed herein a method of installing an infill-based overlay system,comprising: contacting a layer of geotextile fabric to the surface of asubstrate; applying a first adhesive layer to the surface of thegeotextile fabric; adding an infill layer comprising sand, rubber, or arubber alternative, or a combination thereof to the first adhesivelayer; applying a second adhesive to the infill layer; applying a firstlayer of a resurfacer; applying a second layer of resurfacer; applying afirst layer of color; applying a second layer of color; applying a thirdlayer of color; and providing playing lines on the surface of theoverlay.

Disclosed herein a method of installing an infill-based overlay system,comprising: correcting one or more deformations in the substrate;contacting the substrate with two or more pieces of geotextile fabric;inserting a seaming material under the edges of two adjacent pieces ofgeotextile fabric; applying a first adhesive layer to the top surface ofthe seaming material; contacting the two adjacent pieces of geotextilefabric with the adhesive on the top surface of the seaming material;applying pressure to the seam of the two adjacent pieces of geotextilefabric to create a layer of seamed geotextile fabric; applying a secondadhesive layer to the surface of the layer of seamed geotextile fabric;adding an infill layer comprising sand, rubber, or a rubber alternative,or a combination thereof to the second adhesive layer; applying a thirdadhesive layer to the surface of the infill layer; applying at least onelayer of a resurfacer; applying at least one layer of color; andproviding playing lines on the surface of the overlay.

2. Infill Layers

Disclosed herein a method of installing an infill-based overlay system,comprising: contacting a layer of geotextile fabric to the surface of asubstrate; applying a first adhesive layer to the surface of thegeotextile fabric; adding a first infill layer comprising sand, rubber,or a rubber alternative, or a combination thereof to the first adhesivelayer; applying a second adhesive layer to the first infill layer;adding a second infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof to the second adhesive layer;applying a third adhesive layer to the second infill layer; applying atleast one layer of a resurfacer; and providing playing lines on thesurface of the overlay.

Disclosed herein a method of installing an infill-based overlay system,comprising: contacting a layer of geotextile fabric to the surface of asubstrate; applying a first adhesive layer to the surface of thegeotextile fabric; adding a first infill layer comprising sand, rubber,or a rubber alternative, or a combination thereof to the first adhesivelayer; applying a second adhesive layer to the first infill layer;adding a second infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof to the second adhesive layer;applying a third adhesive layer to the second infill layer; applying afirst layer of a resurfacer; applying a second layer of a resurfacer;and providing playing lines on the surface of the overlay.

Disclosed herein a method of installing an infill-based overlay system,comprising: contacting a layer of geotextile fabric to the surface of asubstrate; applying a first adhesive layer to the surface of thegeotextile fabric; adding a first infill layer comprising sand, rubber,or a rubber alternative, or a combination thereof to the first adhesivelayer; applying a second adhesive layer to the first infill layer;adding a second infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof to the second adhesive layer;applying a third adhesive layer to the second infill layer; applying afirst layer of a resurfacer; applying a second layer of a resurfacer;applying at least one layer of color; and providing playing lines on thesurface of the overlay.

Disclosed herein a method of installing an infill-based overlay system,comprising: contacting a layer of geotextile fabric to the surface of asubstrate; applying a first adhesive layer to the surface of thegeotextile fabric; adding a first infill layer comprising sand, rubber,or a rubber alternative, or a combination thereof to the first adhesivelayer; applying a second adhesive layer to the first infill layer;adding a second infill layer comprising sand, rubber, or a combinationof sand and rubber to the second adhesive layer; applying a thirdadhesive layer to the second infill layer; applying a first layer of aresurfacer; applying a second layer of a resurfacer; applying a firstlayer of color; applying a second layer of color; and providing playinglines on the surface of the overlay.

Disclosed herein a method of installing an infill-based overlay system,comprising: contacting a layer of geotextile fabric to the surface of asubstrate; applying a first adhesive layer to the surface of thegeotextile fabric; adding a first infill layer comprising sand, rubber,or a combination of sand and rubber to the first adhesive layer;applying a second adhesive layer to the first infill layer; adding asecond infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof to the second adhesive layer; applying a thirdadhesive layer to the second infill layer; applying a first layer of aresurfacer; applying a second layer of a resurfacer; applying a firstlayer of color; applying a second layer of color; applying a third layerof color; and providing playing lines on the surface of the overlay.

Disclosed herein a method of installing an infill-based overlay system,comprising: contacting a layer of geotextile fabric to the surface of asubstrate; applying a first adhesive layer to the surface of thegeotextile fabric; adding a first infill layer comprising sand, rubber,or a rubber alternative, or a combination thereof to the first adhesivelayer; applying a second adhesive layer to the first infill layer;adding a second infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof to the second adhesive layer;applying a third adhesive layer to the second infill layer; adding athird infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof to the third adhesive layer; applying a fourthadhesive layer to the third infill layer; applying a first layer of aresurfacer; applying a second layer of a resurfacer; applying a firstlayer of color; applying a second layer of color; applying a third layerof color; and providing playing lines on the surface of the overlay.

Disclosed herein a method of installing an infill-based overlay system,comprising: correcting one or more deformations in the substrate;contacting the substrate with two or more pieces of geotextile fabric;inserting a seaming material under the edges of two adjacent pieces ofgeotextile fabric; applying a first adhesive layer to the top surface ofthe seaming material; contacting the two adjacent pieces of geotextilefabric with the adhesive on the top surface of the seaming material;applying pressure to the seam of the two adjacent pieces of geotextilefabric to create a layer of seamed geotextile fabric; applying a secondadhesive layer to the surface of the layer of seamed geotextile fabric;adding a first infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof to the second adhesive layer;applying a third adhesive layer to the surface of the first infilllayer; adding a second infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof to the second adhesive layer;applying a fourth adhesive layer to the surface of the second infilllayer; applying at least one layer of a resurfacer; applying at leastone layer of color; and providing playing lines on the surface of theoverlay.

3. Infill Layers

Disclosed herein a method of installing an infill-based overlay system,comprising: contacting a layer of geotextile fabric to the surface of asubstrate; applying a first adhesive layer to the surface of thegeotextile fabric; adding a first infill layer comprising sand, rubber,or a rubber alternative, or a combination thereof to the first adhesivelayer; applying a second adhesive layer to the first infill layer;adding a second infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof to the second adhesive layer;applying a third adhesive layer to the second infill layer; adding athird infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof to the third adhesive layer; applying a fourthadhesive layer to the third infill layer; applying at least one layer ofa resurfacer; and providing playing lines on the surface of the overlay.

Disclosed herein a method of installing an infill-based overlay system,comprising: contacting a layer of geotextile fabric to the surface of asubstrate; applying a first adhesive layer to the surface of thegeotextile fabric; adding a first infill layer comprising sand, rubber,or a rubber alternative, or a combination thereof to the first adhesivelayer; applying a second adhesive layer to the first infill layer;adding a second infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof to the second adhesive layer;applying a third adhesive layer to the second infill layer; adding athird infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof to the third adhesive layer; applying a fourthadhesive layer to the third infill layer; applying a first layer of aresurfacer; applying a second layer of a resurfacer; and providingplaying lines on the surface of the overlay.

Disclosed herein a method of installing an infill-based overlay system,comprising: contacting a layer of geotextile fabric to the surface of asubstrate; applying a first adhesive layer to the surface of thegeotextile fabric; adding a first infill layer comprising sand, rubber,or a rubber alternative, or a combination thereof to the first adhesivelayer; applying a second adhesive layer to the first infill layer;adding a second infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof to the second adhesive layer;applying a third adhesive layer to the second infill layer; adding athird infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof to the third adhesive layer; applying a fourthadhesive layer to the third infill layer; applying a first layer of aresurfacer; applying a second layer of a resurfacer; applying at leastone layer of color; and providing playing lines on the surface of theoverlay.

Disclosed herein a method of installing an infill-based overlay system,comprising: contacting a layer of geotextile fabric to the surface of asubstrate; applying a first adhesive layer to the surface of thegeotextile fabric; adding a first infill layer comprising sand, rubber,or a rubber alternative, or a combination thereof to the first adhesivelayer; applying a second adhesive layer to the first infill layer;adding a second infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof to the second adhesive layer;applying a third adhesive layer to the second infill layer; adding athird infill layer comprising sand, rubber, or a rubber alternative, ora combination thereof to the third adhesive layer; applying a fourthadhesive layer to the third infill layer; applying a first layer of aresurfacer; applying a second layer of a resurfacer; applying a firstlayer of color; applying a second layer of color; and providing playinglines on the surface of the overlay.

Disclosed herein a method of installing an infill-based overlay system,comprising: correcting one or more deformations in the substrate;contacting the substrate with two or more pieces of geotextile fabric;inserting a seaming material under the edges of two adjacent pieces ofgeotextile fabric; applying a first adhesive layer to the top surface ofthe seaming material; contacting the two adjacent pieces of geotextilefabric with the adhesive on the top surface of the seaming material;applying pressure to the seam of the two adjacent pieces of geotextilefabric to create a layer of seamed geotextile fabric; applying a secondadhesive layer to the surface of the layer of seamed geotextile fabric;adding a first infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof to the second adhesive layer;applying a third adhesive layer to the surface of the first infilllayer; adding a second infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof to the second adhesive layer;applying a fourth adhesive layer to the surface of the second infilllayer; adding a third infill layer comprising sand, rubber, or a rubberalternative, or a combination thereof to the second adhesive layer;applying a fifth adhesive layer to the surface of the third infilllayer; applying at least one layer of a resurfacer; applying at leastone layer of color; and providing playing lines on the surface of theoverlay.

Steps of Disclosed Methods of Installing Disclosed Overlay Systems

Disclosed herein are steps that are relevant to the disclosed methods ofinstalling an overlay system.

Correcting a Deformity

In an aspect, a deformation can comprise a structural crack, adepression, a low spot, a high spot, a “dead spot”, etc. In an aspect, adisclosed method can comprise correcting one or more deformations in theexisting substrate. In an aspect, correcting one or more deformations inthe existing substrate can comprise cleaning the surface of thesubstrate and removing any loose debris, such as dust, dirt, gravel,crumbled asphalt, or concrete. In an aspect, removing any loose debriscan comprise using a power washer. For example, in an aspect, adiscernible crack or depression can be clean and filled with acomposition that adheres to the substrate. In an aspect, a compositioncan comprise a combination of acrylic latex, cement (e.g., Portlandcement), and silica sand. In an aspect, such a composition can bereferred to as patch binder, a term familiar to the art. In an aspect, acomposition can comprise an acrylic emulsion. In an aspect, correctingone or more deformations in the existing substrate can improve theplanarity of the playing surface. Correcting one or more deformations inthe existing substrate can also improve the uniformity of infill layers,thereby ensuring that an infill layer is saturated with an adhesive.

Cleaning a Substrate

In an aspect, a disclosed method can comprise cleaning the substrateprior to installing the overlay system. For example, if the substratepresents debris, dirt, vegetation, mold, mildew, or fungus, then thesubstrate can be cleaned. Even in the absence of debris, dirt,vegetation, mold, mildew, or fungus, the substrate can be cleaned. In anaspect, cleaning the substrate can comprise using a broom, a vacuum, ablower, or a pressure washer, or a combination thereof to remove anydebris, dirt, vegetation, mold, mildew, or fungus from the substrateincluding within cracks and other deformations. In an aspect, cleaningthe substrate can comprise scrubbing the substrate with brushes, brooms,or other comparable equipment and using a bleach-based solution. In anaspect, cleaning the substrate can comprise thoroughly rinsing (e.g.,using a pressure washer) the substrate. Or, in an aspect, cleaning thesubstrate can comprise a combination of these techniques.

Contacting the Substrate

In an aspect, contacting the substrate with two or more pieces ofgeotextile fabric can comprise rolling out two or more pieces ofgeotextile fabric. In an aspect, the two or more pieces of geotextilefabric can be rolled out from the center of any playing surface or courttowards the periphery of the playing surface or court. In an aspect, thetwo or more pieces of geotextile fabric can be rolled out in from theperiphery of any playing surface or court towards the center of anyplaying surface or court. In an aspect, the one or more pieces ofgeotextile fabric can be rolled out in an alternating fashion.

For example, a single tennis court measures approximately 60 feet inwidth by 120 feet in length. In an aspect, a disclosed method cancomprising rolling out a first piece of geotextile fabric along a fenceline of 120 feet, rolling out a second piece of geotextile fabric alongthe edge of the first piece, rolling out a third piece of geotextilefabric along the opposite fence line of 120 feet, and rolling out afourth piece of geotextile fabric alongside of the third piece ofgeotextile fabric, allowing any excess material to overlap thepreviously rolled out second piece of geotextile. In an aspect, adisclosed method can comprise removing any overlap that occurs betweentwo pieces of geotextile fabric. In an aspect, removal of any overlapthat occurs between two pieces of geotextile fabric can allow forseaming of those two pieces. FIG. 3 shows (A) an exemplary rolloutpattern of pieces of geotextile fabric for a tennis court, (B) theoverlap of two pieces of geotextile fabric, and (C) the seam that willbe created following the cut in the overlap shown in (B).

In an aspect, a disclosed method can comprising rolling out a firstpiece of geotextile fabric along the center line of a playing surface,rolling out a second piece of geotextile fabric along the center line ofa playing surface (which is also flush to the first piece), rolling outa third piece of geotextile fabric alongside the first piece ofgeotextile fabric such that it runs along a fence line or the edge ofthe playing surface, and rolling out a fourth piece of geotextile fabricalongside of the second piece of geotextile fabric such that it runsalong the opposite fence line or the opposite edge of the playingsurface.

In an aspect, a disclosed method can comprising rolling out a firstpiece of geotextile fabric alongside a fence line or the edge of aplaying surface, rolling out a second piece of geotextile fabricalongside the first piece of geotextile fabric, rolling out a thirdpiece of geotextile fabric alongside the second piece of geotextilefabric, and rolling out a fourth piece of geotextile fabric alongsidethe third piece of geotextile fabric such that the fourth piece alsoruns along a fence line or the edge of the playing surface.

In an aspect, the number of pieces of geotextile fabric to be rolled outcan vary in accordance with the size of the playing surface or court.For example, in an aspect, a larger court or playing surface can requiremore pieces of geotextile fabric to be rolled out whereas a smallercourt or playing surface can require less pieces of geotextile fabric tobe rolled out.

Seaming the Geotextile Fabric

In an aspect, seaming two or more pieces of geotextile fabric to createa layer of seamed geotextile fabric comprises inserting a seamingmaterial under the edges of two adjacent pieces of geotextile fabric;applying a first adhesive layer to the top surface of the seamingmaterial; contacting the two adjacent pieces of geotextile fabric withthe adhesive on the top surface of the seaming material; applyingpressure to the seam of the two adjacent pieces of geotextile fabric tocreate the layer of seamed geotextile fabric. In an aspect, a fiberglassmesh can be placed on top of the seam made by two pieces of abuttinggeotextile fabric. Thus, in an aspect, a completed seam of two pieces ofgeotextile fabric can comprise a seaming material on the bottom side ofthe seam and a fiberglass mesh on the top side of the seam.

In an aspect, inserting a seaming material under the edges of twoadjacent pieces of geotextile fabric can comprise rolling back the edgesof both pieces of geotextile fabric to be seamed and positioning theseaming material so that seaming material evenly or about evenlycontacts both pieces of geotextile fabric. In an aspect, an adhesive canbe applied to the top surface of the seaming material and the edges ofboth pieces of geotextile fabric can be rolled onto the seamingmaterial. For example, squeegees designed for sport surfacing arecommercially available. In an aspect, a squeegee can comprise a rubberblade with a tapered or rounded edge that is about 50 to about 60durometer. In an aspect, applying an adhesive to the seaming materialcan comprise using a trowel, such as, for example, a toothed trowel. Inan aspect, applying an adhesive to the seaming material can compriseusing a notched squeegee or a glue box, both of which are known to theart. An example prior art notched squeegee 500 is shown in FIG. 5. In anaspect, applying an adhesive to the seaming material can compriseapplying a thin layer of adhesive.

In an aspect, applying pressure to the seam of the adjoining pieces ofgeotextile fabric can comprise using a weighted walk behind roller. Inan aspect, applying pressure to the seamed geotextile fabric can occurimmediately after both pieces of geotextile fabric have been laid uponthe seaming material. In an aspect, applying pressure to the seamedgeotextile fabric can occur soon thereafter after both pieces ofgeotextile fabric have been laid upon the seaming material.

In an aspect, the two adjacent pieces of geotextile fabric can bestitched together using threads or filaments known to the art including,but not limited to, polypropylene, polyester, fiberglass, andpolyethylene threads or filaments.

Adhering a Layer of Geotextile Fabric

In an aspect of a disclosed method of installing a disclosed overlaysystem, partially adhering or substantially adhering the geotextilefabric to a substrate can occur after the inserting a seaming materialunder the edges of two adjacent pieces of geotextile fabric to create alayer of seamed geotextile fabric. In an aspect, partially adhering orsubstantially adhering the geotextile fabric can comprise adhering aseamed layer of geotextile fabric. The seam itself, however, is notadhered to a substrate.

In an aspect, contacting the substrate with two or more pieces ofgeotextile fabric or a seamed piece of geotextile fabric can comprisepartially adhering or substantially adhering the geotextile fabric tothe substrate. In an aspect, partially adhering or substantiallyadhering the geotextile fabric to the substrate can comprise using anadhesive as disclosed herein (e.g., a liquid polymer such as acarboxylated styrene-butadiene emulsion, a self-crosslinkingcarboxylated styrene-butadiene, or a polyurethane constructionadhesive). In an aspect, using an adhesive to partially adhere orsubstantially adhere the geotextile fabric to the substrate can compriseapplying an adhesive to the perimeter of the edges of a layer of seamedgeotextile fabric. In an aspect, using an adhesive to partially adhereor substantially adhere the geotextile fabric to the substrate cancomprise applying an adhesive to the perimeter of one or more pieces ofgeotextile fabric.

Applying can comprise using a trowel, such as, for example, a toothedtrowel. In an aspect, applying an adhesive to the perimeter of one ormore edges of the layer of seamed geotextile fabric can comprisecontinuous or non-continuous application of the adhesive. In an aspect,an adhesive can be non-continuously applied to a pre-determined lengthof the perimeter of the layer of seamed geotextile fabric. In otherwords, an adhesive can be applied to alternating pre-determined lengthsof the perimeter. For example, an adhesive can be applied for to apre-determined length of the perimeter of the layer of seamed geotextilefabric and not applied to the immediately adjacent pre-determined lengthof the perimeter. Accordingly, an adhesive can be applied to the entireperimeter of the layer in an alternating “on”/“off” pattern. FIG. 4shows (A) the “on”/“off” pattern of an adhesive (e.g., non-continuousapplication) around the perimeter of a rectangular shaped overlay, and(B) shows the continuous application of an adhesive around the perimeterof a rectangular shaped overlay.

In an aspect, the pre-determined length can be about 6″ to about 24″ ofthe perimeter, about 10″ to about 20″ of the perimeter, or about 12″ toabout 18″ of the perimeter of the layer of seamed geotextile fabric. Inan aspect, the pre-determined length can be about 6″, about 10″, about12″, about 18″, or about 24″ of the perimeter of the layer of seamedgeotextile fabric. In an aspect, the pre-determined length can be about12″, about 18″, or about 24″ of the perimeter of the layer of seamedgeotextile fabric. In an aspect, the pre-determined length can be about12″ of the perimeter of the layer of seamed geotextile fabric.

In an aspect, an adhesive can be applied for a pre-determined width fromone or more the edges of the layer of the seamed geotextile fabrictowards the center of the layer. In an aspect, an adhesive can beapplied for a pre-determined width from the perimeter of the layer ofthe seamed geotextile fabric towards the center of the layer. In anaspect, the pre-determined width can be about 3″ to about 30″, about 6″to about 27″, about 9″ to about 24″, about 12″ to about 21″, or about15″ to about 18″ of the perimeter of the layer of seamed geotextilefabric. In an aspect, the pre-determined width can be about 3″, about6″, about 10″, or about 12″ of the perimeter of the layer of seamedgeotextile fabric. In an aspect, the pre-determined width can be about6″ of the perimeter of the layer of seamed geotextile fabric.

In an aspect, applying an adhesive layer to the surface of the seamedgeotextile fabric can comprise using a pneumatic powered spray rig. Inan aspect, applying an adhesive layer to an infill layer can compriseusing a pneumatic powered spray rig.

In an aspect, partially adhering or substantially adhering thegeotextile fabric to the substrate can comprise using a mechanical meansof fixation. Mechanical means of fixation are known to those skilled inthe art and include, but are not limited to, nails, screws, stakes,hooks, and pins. In an aspect, using a mechanical means of fixation topartially adhere or substantially adhere the geotextile fabric to thesubstrate can comprise applying the mechanical means of fixation to theperimeter of the edges of a layer of seamed geotextile fabric. In anaspect, using mechanical means of fixation to partially adhere orsubstantially adhere the geotextile fabric to the substrate can compriseapplying the mechanical means of fixation to the perimeter of one ormore pieces of geotextile fabric. In an aspect, applying the mechanicalmeans of fixation to the perimeter of one or more edges of the layer ofseamed geotextile fabric can comprise continuous or non-continuousapplication of the mechanical means of fixation. In an aspect, amechanical means of fixation can be non-continuously applied to apre-determined length of the perimeter of the layer of geotextilefabric. In other words, the mechanical means of fixation can be appliedto alternating pre-determined intervals along the perimeter. In anaspect, the pre-determined interval can be every 3″, every 6″, every 9inches, every 12″, every 18″, or every 24″, or between every 3″ and 9″,or between every 6″ and 12″, or between every 12″ and 18″, or betweenevery 18″ and 24″.

In an aspect of a method of installing a disclosed overlay, contactingthe substrate with two or more pieces of geotextile fabric or a seamedpiece of geotextile fabric can comprise positioning the geotextilefabric on the substrate but not adhering it to the substrate.

Applying an Adhesive

In an aspect, applying an adhesive layer to the surface of the layer ofseamed geotextile fabric can comprise saturating the layer of seamedgeotextile fabric and allowing the saturated layer of geotextile fabricto dry. In an aspect, whether the geotextile fabric is dry can bedetermined by touch. In an aspect, applying an adhesive layer to thesurface of any other layer can comprise saturating or coating the otherlayer with adhesive and allowing saturated or coated other layer to dry.In an aspect, drying can comprise about 1-3 hours. For example, in sunnyand/or low-humidity weather, drying can comprise about 1 hour. In anaspect, in cloudy and/or high-humidity weather, drying can compriseabout 24 hours. In an aspect, in cloudy and/or high humidity weather,drying can comprise about 24 hours for each layer.

Preparing the Binder Layer

In an aspect, a disclosed method can comprise preparing one or morebinder layers. Binder layers are discussed herein and can be prepared soas to satisfy the desired properties of the resulting overlay. A binderlayer can be prepare at time of application or some other time prior toapplication.

In an aspect, an infill layer can be applied to the entire surface of apre-existing layer. In an aspect, an infill layer can be applied byusing, for example, a squeegee or a similar instrument known to the art.In an aspect, applying an infill layer can comprise spreading the sand,rubber, or combination of sand and rubber across the entire surface of apre-existing layer. In an aspect, spreading the sand across the surfaceof the geotextile fabric can comprising using a squeegee or a similarinstrument known to the art or a straight edge or screed, or acombination of both a squeegee and straight edge or screed. In anaspect, a squeegee can be used first and a straight edge or screed canbe used second. An example prior art squeegee 600 is shown in FIG. 6,and an example prior art straight edge or screed 700 is shown in FIG. 7.

In an aspect, applying an adhesive layer to infill layer can compriseminimal displacement of the infill layer.

In an aspect, applying an adhesive layer to an infill layer can compriseapplying a liberal amount of adhesive. In an aspect, applying anadhesive layer to an infill layer can comprise applying a sufficientamount of adhesive so as to completely saturate or nearly completelysaturate the infill layer. In an aspect, a sufficient amount of anadhesive layer can vary according on one or more factors, such as, butnot limited to, the depth of the infill layer. In an aspect, the depthof the infill layer can vary according to one or more factors, such asthe degree of deformities of the existing substrate.

In an aspect, a disclosed method can comprise applying a first infilllayer. In an aspect, a disclosed method can comprise applying a secondinfill layer. A second infill layer can comprise sand, rubber, or acombination of sand and rubber. In an aspect, a second infill layer canbe applied to the entire surface of a pre-existing layer. In an aspect,a second infill layer can be applied by using, for example, a squeegeeor a similar instrument known to the art. In an aspect, a second infilllayer can be applied for one or more reasons. For example, in an aspect,a second infill layer can be applied if some or all of the first infilllayer becomes displaced during installation. In an aspect, a secondinfill layer can be applied if some or all of the first infill layer isnot flush with the fibers of the layer of geotextile fabric. In anaspect, a second infill layer can be applied if some or all of the firstinfill layer comprises crumb rubber. In an aspect, a second infill layercan be applied if some or all of the first infill layer exceeds ¾″ inchin depth. In an aspect, a disclosed method can comprise applying a thirdinfill layer. A third infill layer can comprise sand, rubber, or acombination of sand and rubber. In an aspect, a third infill layer canbe applied to the entire surface of a pre-existing layer. In an aspect,a third infill layer can be applied by using, for example, a squeegee ora similar instrument known to the art. In an aspect, a third infilllayer can be applied for one or more reasons. For example, in an aspect,a third infill layer can be applied if some or all of the first infilllayer and/or the second infill layer becomes displaced duringinstallation. In an aspect, a third infill layer can be applied if someor all of the first infill layer and/or second infill layer is not flushwith the fibers of the layer of geotextile fabric. In an aspect, a thirdinfill layer can be applied if some or all of the first infill layerand/or second infill comprises crumb rubber. In an aspect, a thirdinfill layer can be applied if some or all of the first infill layerand/or second infill layer exceeds ¼″ inch in depth.

In an aspect, applying an infill layer to a pre-existing layer cancomprise using a squeegee or a similar instrument known to the art or astraight edge or screed, or a combination of both a squeegee andstraight edge or screed. In an aspect, a squeegee can be used first anda straight edge or screed can be used second.

In an aspect, a disclosed method can comprise applying a first layer ofresurfacer, applying a second layer of resurfacer, applying a firstlayer of color, applying a second layer of color, applying a third layerof color, providing playing lines on the surface of the overlay (e.g.,lines for a tennis court, lines for a basketball court), or acombination thereof. In an aspect, applying one or more surface coatingscan comprise using a squeegee.

In an aspect, weather can affect the installation of a disclosed overlaysystem. In an aspect, a disclosed method can be completed in about 2days, about 3 days, about 4 days, about 5 days, about 6 days, or about 7days. In an aspect, the amount of time required to complete a step of adisclosed method can be affected by the size of the overlay system, byweather, or by a combination thereof. For example, it if rains duringinstallation of a disclosed overlay system, then the installation can bedelayed so that the overlay can thoroughly dry. In an aspect, if thetemperature falls below about 50° F., then the installation of adisclosed overlay system can be delayed. Low temperatures can affect thecuring of surface coatings and adhesives. In an aspect, if the surfacetemperature rises above 150° F., then the installation of a disclosedoverlay system can be delayed. High surface temperatures can affect theintegrity of surface coatings.

Preparing an Infill Layer

In an aspect, a disclosed method can comprise preparing one or moreinfill layers. Infill layers are discussed herein and can be prepared soas to satisfy the desired properties of the resulting overlay. An infilllayer can be prepare at time of application or some other time prior toapplication.

Advantages of the Disclosed Overlay Systems and Disclosed Methods ofInstalling Overlay Systems

As described herein, the overlay system provides several advantages overthe existing art. The disclosed overlay system are customizable and canprovide long-term crack repair, cushion, or both for athletic courts andrunning tracks.

Traditional overlay systems are rolled out and then seamed on the topsurface. Accordingly, in traditional overlay systems, the material usedfor seaming the parts of the overlay systems are exposed to all of thesurface traffic of the playing surface. Such exposure can result inpremature failure of the surface due to a failed or compromised seam.Conversely, the overlay system disclosed herein comprises a layer ofgeotextile fabric that is seamed on the bottom surface of the fabric.The seaming along the bottom surface provides a more uniform topsurface. In an aspect, only after the pieces of geotextile fabric havebeen seamed together along the bottom surface and fiberglass mesh hasbeen added to the top of the seam, then the subsequent layers of thedisclosed overlay system are installed. Thus, in an aspect, the overlaysystems disclosed herein can be considered a monolithically installedsurface or cast-in-place surface. Cast-in-place systems confer theadvantage of being able to customize the overlay at the time ofinstallation, especially in view of climate considerations. In otherwords, every layer but for the layer of geotextile fabric is installedas one continuous piece having no seams. Consequently, the overlaysystem disclosed herein provides superior strength, durability, andflexibility. Moreover, installation of the disclosed overlay systemrequires lighter materials that can be handled without the use of heavymachinery.

For example, the layer of geotextile fabric of the overlay systemdisclosed herein can occupy minor depressions in the surface of asubstrate (such as a new or existing base comprising concrete, asphalt,gravel, clay, wood, or tile, or a combination thereof).

Several existing systems have a fixed height. This means that a systemhaving a ½ inch thick rubber mat type overlay would simply span acrosssuch a depression or low spot. Because the rubber mat type overlay doesnot physically occupy or fill the depression or the low spot, thespanned depression or low spot becomes a “dead spot” in the completedsystem. As known to the art, a “dead spot” is an area underneath anoverlay (or a cushioned system) wherein the substrate has a depressionor a low spot that is not physically occupied by the overlay. A “deadspot” in the substrate can be created with as little as a ⅛″ inchdepression or low spot in the substrate as compared to surrounding spotsof the substrate. A ball that hits a dead spot will act much differentlythan when the same ball does not hit a dead spot. Dead spots in aplaying surface are frustrating to players.

Similarly, if the substrate has a high spot, the same ½ inch thickrubber mat type overlay will simply span across such a high spot.Because the rubber mat type overlay does not adjust to accommodate sucha high spot in the substrate, the completed system will retain that highspot, thereby affecting the planarity of the system.

The flexibility of the overlay systems disclosed herein overcome theproblems associated with fixed height systems. For example, in anaspect, the geotextile fabric of the disclosed overlay system can becontoured to the surface of the substrate. The flexibility andpliability of the geotextile fabric can help to convey this contouringcapability. For example, if a substrate comprises a depression or a lowspot, then the depression or the low spot can be corrected duringinstallation over the overlay system. In an aspect, an infill layer canbe made slightly thicker at a depression or a low spot. By adjusting aninfill layer at a depression or low spot in the underlying substrate,the overlay system disclosed herein can provide better planarity thanexisting system. Similarly, by adjusting an infill layer at a high spotin the underlying substrate, the overlay system disclosed herein canprovide better planarity than existing systems having fixed heights. Inan aspect, by occupying or “falling” into minor depressions in thesurface of the substrate, the layer of geotextile fabric can provideprotection against “dead spots” in the surface. By employing thecustomizable overlay system disclosed herein, it is not necessary toreplace or destroy the existing substrate or damaged existing substrateprior to the installation of the disclosed overlay system. This resultsin a substantial financial savings. Similarly, the disclosed overlaysystem can also accommodate cracks that develop following installationin the existing substrate or damaged existing substrate or that developin a new substrate. Thus, the flexibility of the overlay systemsdisclosed herein provided improved planarity over existing systems.

As the overlay systems disclosed herein are not entirely adhered to theunderlying substrate, the disclosed systems eliminate the need to removeone or more pre-existing layers of color coatings prior to installation.Typically, when existing substrates have 12 or more layers of coatings,there is a very high risk that hydrostatic pressure will push off thelayers of coatings, thereby causing cracks in the substrate. By notfully adhering the disclosed overlay to the substrate, any cracks in theunderlying substrate will not reflect through the overlay system. Thus,the overlay systems disclosed herein can be considered to be“crack-free” surfaces.

The overlay systems disclosed herein provide both strength andflexibility. For example, the disclosed overlay systems demonstratesurprising horizontal strength that provides a degree of stiffness thatspans across any cracks in the underlying substrate while maintainingthe vertical flexibility to occupy depressions or low spots in thesubstrate. This type of vertical flexibility also eliminates any bouncethat may occur between the underlying substrate and the disclosedoverlay. When a ball hits the playing surface, even a minor bounce willcreate a hollow sound that users find irksome.

As discussed above, the disclosed overlay systems are customizable. Theability to customize the content of the one or more binder layers or theone or more infill layers confers design flexibility to the overlaysystem, and distinguishes the disclosed overlay system from other,inferior systems. For example, in an aspect of the binder-based overlaysystem, each of the one or more binder layers can comprise acustomizable amount of sand, rubber, rubber alternative, or acombination thereof. For example, if a harder surface is desired, thenthe one or more binder layers can contain more sand than rubber orrubber alternative. If a softer surface is desired, then the one or morebinder layers can contain more rubber or rubber alternative than sand.Similarly, in an aspect of the infill-based overlay system, each of theone or more infill layers can comprise a customizable amount of sand,rubber, rubber alternative, or a combination thereof. For example, if aharder surface is desired, then the one or more infill layers cancontain more sand than rubber or rubber alternative. If a softer surfaceis desired, then the one or more infill layers can contain more rubberor rubber alternative than sand. Moreover, the flexibility conferred bythe customization of the disclosed overlay systems prevents thedevelopment of issues of deformities of the underlying substrate fromaffecting the surface of the overlay system.

In an aspect, the disclosed overlay system can be partially adhered orsubstantially adhered to the substrate at the perimeter, or the overlaysystem can be positioned over a substrate but not adhered. Therefore, atany point after installation, the disclosed overlay system can be easilyremoved from the substrate. For example, the disclosed overlay systemcan be rolled away from the substrate thereby allowing for inspection ofthe underlying substrate. Such an inspection can identify one or moreissues with the underlying substrate, such as, for example, structuralcracks, depressions, low spots, high spots, “dead spots”, etc. The oneor more issues identified by the inspection can then be redressedwithout having to entirely replace the overlay system.

Similarly, the flexibility of the disclosed overlay system allows thereplacement of net poles, net pole footings, and other accessories (suchas, for example, basketball hoops) without having to replace the entiresubstrate. Rather, the overlay can be rolled up prior to the repairs,and then rolled out and once again adhered to or positioned over thesubstrate after the repairs.

Moreover, the overlay systems disclosed herein can be advantageouslyused for temporary sporting events. For example, because the disclosedsystems are light-weight and are only partially adhered to theunderlying substrate, the disclosed systems can be used to createtemporary venues for sporting events. In an aspect, a temporary overlaysystem disclosed herein can be adhered to the perimeter of an underlyingsubstrate using a means other than a polyurethane construction adhesive(e.g., double-sided tape). Thus, the overlay system disclosed herein cantemporarily convert any substrate (such as, for example, a gym floor, awood floor, a tile floor, or a concrete floor) into a sporting eventsurface. Following the event, the overlay can be removed therebyexposing the undamaged underlying substrate.

The geotextile fabric of the overlay system can also advantageouslyprovide protection against any thermal shrinking or expanding. Existingoverlay systems cannot accommodate thermal expansion and contraction ofthe underlying substrate. For example, when the substrate experiencesheat, the substrate expands. When the underlying substrate expands, theoverlay is much more likely to tear or be displaced from its originalposition. Similarly, when the substrate contracts, the overlay is muchmore likely to wrinkle. But, as the overlay systems disclosed herein arenot fully adhered to the underlying substrate, the disclosed systems canaccommodate the substrate's thermal expansion and contraction withouttearing, displacing, or wrinkling. Because the disclosed overlay systemsare only partially adhered to the substrate, the disclosed systemsmaintain the surface integrity of the system despite extremetemperatures.

One of the common problems that plague traditional or existing overlaysystems, which are fully adhered to the underlying substrate, is theaccumulation of hydrostatic pressure (commonly known to the art asvapor). Vapor can build up under any layer that is adhered to thesurface. Accumulated or trapped vapor causes bubbles and peelings in theone or more layers of color coating. For example, an asphalt court thathas more than twelve coats of color coating applied to its surface isvery susceptible to damage caused by trapped vapor. The adhesive appliedto these traditional or existing overlay systems prevents thedissipation of this accumulated or trapped vapor, thereby causing damageof the overlay system.

Unlike traditional overlay systems, the disclosed overlay systemprovides for an “escape route” for accumulated or trapped vapor. Becausethe geotextile layer of the overlay systems disclosed herein is notfully adhered to the underlying substrate, accumulated or trapped vaporcan exit through the existing court surface as it would do normally.Furthermore, accumulated or trapped vapor can also travel horizontallybetween the disclosed overlay and the underlying substrate to the edgeof the overlay and escape. Thus, unlike traditional or existing overlaysystems, the customizable overlay systems disclosed here are“breathable” systems.

The lack of a seam on the surface of the overlay system provides anotheradvantage in that the failure of a seam or a joint is unlikely.Similarly, the lack of a seam on the surface of the overlay systemprovides better planarity. Planarity (or the levelness or the flatnessof a surface) is an important consideration of the disclosed overlaysystem as some governing organizations have established strict planarityguidelines. For example, with respect to planarity, the American SportsBuilders Association (ASBA) has stated that “no deviations in courtsurface shall be more than ⅛″ of an inch over 10′ feet.” Although thepieces of geotextile fabric requiring seaming on the bottom of thefabric, all of the subsequent layers in the disclosed overlay system areadded monolithically (i.e., as a solid or unbroken layer).

By building the layers of the disclosed overlay system at the time ofinstallation (i.e., on the surface itself or cast-in-place), theinstallation process can be modified or customized to make any necessarycorrections. For example, as discussed supra, the thickness of an infilllayer or a binder layer can be adjusted at the time of installation toaccommodate for a depression or a low spot or to accommodate for a highspot in the underlying substrate. Unlike the overlay systems disclosedherein, traditional overlay systems in the art simply cannot performthis type of “on-the-spot” modification or customization.

The disclosed overlay systems are also lightweight, which is anotheradvantage over the overlay systems known in the art. As a lightweightsystem, the disclosed overlay system can be installed by hand, therebyeliminating the need for heavy equipment or invasive types of machineryduring installation that damage property and incur additional expense.

Another advantage of the disclosed overlay systems is that it can beinstalled in cooler temperatures than other crack repair systems.Traditional overlay systems that are used to repair cracks are installedby gluing and/or adhering various layers of fabric down over a crack.Typically, these traditional overlay systems can only be installed intemperatures that are at least 60° F. and rising at night. In certaingeographic areas, the temperatures do not exceed 60° F. for sufficienttime to install a traditional overlay system. However, the disclosedoverlay system can be installed in cooler temperatures, such as those,for example, below 60° F. For example, unlike traditional overlaysystems, the overlay system disclosed herein provides for gluing andadhering that is exposed to some degree of airflow. By not trapping theglue or adhesive during the installation, the overlay system disclosedherein can be installed in temperatures that are at least 50° F. andrising at night. This allows for the installation of the disclosedoverlay systems in cooler temperatures.

Another advantage relates to the ability of the disclosed overlay systemto be installed across an entire playing court surface (i.e., abasketball court, a tennis court, etc.). Traditional overlay systems arecommonly installed to redress spot cracks only. Accordingly, othercracks can occur in spots other than the spot cracks redressed by thetraditional overlay system. Using the disclosed overlay system, whichcan be applied to an entire playing court surface, new cracks ordeformities can form and will not reflect through the installed overlaysystem.

Yet another advantage of the overlay systems disclosed herein is thespeed at which an overlay system can be installed. Traditional overlaysystems require 3-4 days to complete the repair of cracks, which is dueto the fact that layers in between the layers of fabric requiresignificant drying time. Only after these layers have completely driedcan the color coatings be applied. Conversely, the overlay systemsdisclosed herein can be installed in one day and color coatings can beapplied the following day. Again, the ease of installation of theoverlay systems disclosed herein provide a cost savings to the consumerbecause labor and travel charges are reduced by the need to be “on-site”for only 1-2 days.

What is claimed is:
 1. A method of installing a binder-based overlaysystem, comprising: contacting a layer of geotextile fabric to a surfaceof a substrate; applying a primer layer to a surface of the geotextilefabric, wherein the primer layer adheres to the geotextile fabric;applying two or more binder layers over the primer layer, wherein thetwo or more binder layers adhere to the primer layer, and wherein atleast one of the two or more binder layers comprise sand, rubber, rubberalternative, or a combination thereof within one or more of styreneacrylic or styrene butadiene; applying a resurfacer layer over the oneor more binder layers and primer layer; seaming two adjacent pieces ofthe geotextile fabric comprising partially adhering or adhering aseaming material across a gap between two adjacent pieces of thegeotextile fabric along an underside of the geotextile fabric pieces toseam the two adjacent piece of geotextile fabric, wherein the seamingmaterial overlaps each of the two adjacent geotextile fabric pieces byat least 3 inches from respective adjacent edges, and wherein the gapbetween two adjacent pieces of the geotextile fabric is seamed along anunderside between the geotextile fabric pieces and the substrate but isnot seamed along an upper side between the geotextile fabric and theprimer layer; applying fiberglass mesh over the gap between two adjacentpieces of the geotextile fabric, wherein the fiberglass mesh extendsover adjacent edges of the pieces of the geotextile fabric defining thegap and is applied prior to or during application of the primer layer,wherein the primer layer is applied with a notched squeegee, and whereinthe two or more binder layers are applied with a squeegee or a straightedge/screed; and wherein the geotextile fabric comprises a polyester,fiberglass yarns, or glass filaments sewn to the upper surface of thegeotextile fabric and that are bi-axially arranged in a grid formation.2. A method of installing a binder-based overlay system, comprising:contacting a layer of geotextile fabric to a surface of a substrate,applying a primer layer to a surface of the geotextile fabric, whereinthe primer layer adheres to the geotextile fabric; applying two or morebinder layers over the primer laver, wherein the two or more binderlavers adhere to the primer layer, and wherein at least one of the twoor more binder layers comprise sand, rubber, rubber alternative, or acombination thereof within one or more of styrene acrylic or styrenebutadiene; applying a resurfacer layer over the one or more binderlavers and primer layer; and seaming two adjacent pieces of thegeotextile fabric comprising partially adhering or adhering a seamingmaterial across a gap between two adjacent pieces of the geotextilefabric along an underside of the geotextile fabric pieces to seam thetwo adjacent piece of geotextile fabric, wherein the seaming materialoverlaps each of the two adjacent geotextile fabric pieces by at least 3inches from respective adjacent edges, and wherein the gap between twoadjacent pieces of the geotextile fabric is seamed along an undersidebetween the geotextile fabric pieces and the substrate but is not seamedalong an upper side between the geotextile fabric and the primer layer.3. The method of claim 2, further comprising applying fiberglass meshover the gap between two adjacent pieces of the geotextile fabric,wherein the fiberglass mesh extends over adjacent edges of the pieces ofthe geotextile fabric defining the gap and is applied prior to or duringapplication of the primer layer.
 4. The method of claim 3, wherein theprimer layer is applied with a notched squeegee.
 5. The method of claim4, wherein the geotextile fabric comprises a polyester, fiberglassyarns, or glass filaments sewn to the upper surface of the geotextilefabric and that are bi-axially arranged in a grid formation.
 6. A methodof installing a binder-based overlay system, comprising: contacting alayer of geotextile fabric to a surface of a substrate; applying aprimer layer to a surface of the geotextile fabric, wherein the primerlayer adheres to the geotextile fabric; applying two or more binderlayers over the primer layer, wherein the two or more binder layersadhere to the primer laver, and wherein at least one of the two or morebinder layers comprise sand, rubber, rubber alternative, or acombination thereof within one or more of styrene acrylic or styrenebutadiene; applying a resurfacer layer over the one or more binderlayers and primer layer; and seaming two adjacent pieces of thegeotextile fabric comprising partially adhering or adhering a seamingmaterial across a gap between two adjacent pieces of the geotextilefabric along an underside of the geotextile fabric pieces to seam thetwo adjacent piece of geotextile fabric, wherein seaming the twoadjacent pieces of geotextile fabric further comprises: inserting aself-adhesive seaming material under adjacent edges of two adjacentpieces of geotextile fabric; and applying pressure to the seam of thetwo adjacent pieces of geotextile fabric to create the layer of seamedgeotextile fabric.
 7. The method of claim 6, wherein the seamingmaterial overlaps each of the two adjacent geotextile fabric pieces byat least 3 inches from respective adjacent edges.
 8. A method ofinstalling a binder-based overlay system, comprising: contacting a layerof geotextile fabric to a surface of a substrate; applying a primerlayer to a surface of the geotextile fabric, wherein the primer layeradheres to the geotextile fabric; applying two or more binder layersover the primer layer, wherein the two or more binder layers adhere tothe primer layer, and wherein at least one of the two or more binderlayers comprise sand, rubber, rubber alternative, or a combinationthereof within one or more of styrene acrylic or styrene butadiene; andapplying a resurfaces layer over the one or more binder layers andprimer layer, wherein a gap between two adjacent pieces of thegeotextile fabric is seamed along an underside between the geotextilefabric pieces and the substrate but is not seamed along an upper sidebetween the geotextile fabric and the primer layer.
 9. The method ofclaim 6, wherein the geotextile fabric comprises a polyester, fiberglassyarns, or glass filaments.
 10. The method of claim 9, wherein thepolyester, fiberglass yarn, or glass filaments are sewn to the uppersurface of the geotextile fabric.
 11. The method of claim 10, whereinthe polyester, fiberglass yarn, or glass filaments are bi-axiallyarranged in a grid formation.
 12. The method of claim 6, wherein theprimer layer is applied with a notched squeegee.
 13. The method of claim12, wherein the two or more binder layers are applied with a squeegee ora straight edge/screed.
 14. A method of installing a binder-basedoverlay system, comprising: contacting a layer of geotextile fabric to asurface of a substrate; applying a primer layer to a surface of thegeotextile fabric, wherein the primer layer adheres to the geotextilefabric; applying two or more binder layers over the primer layer,wherein the two or more binder lavers adhere to the primer layer, andwherein at least one of the two or more binder layers comprise sand,rubber, rubber alternative, or a combination thereof within one or moreof styrene acrylic or styrene butadiene; applying a resurfacer layerover the one or more binder layers and primer layer; and applyingfiberglass mesh over a gap between two adjacent pieces of the geotextilefabric, wherein the fiberglass mesh extends over adjacent edges of thepieces of the geotextile fabric defining the gap.
 15. The method ofclaim 14, wherein the fiberglass mesh is applied prior to or duringapplication of the primer layer.
 16. The method of claim 15, wherein theprimer layer is applied with a notched squeegee, and wherein the two ormore binder layers are applied with a squeegee or a straightedge/screed.
 17. The method of claim 16, wherein the binder has aviscosity of 12,000 centipose to 50,000 centipose.